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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 253 records · Page 14
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Design and Modeling of an 80 bar Oxy-Combustor for Direct Fired Supercritical CO2 Applications

As supercritical CO2 power cycles for fossil energy power generation continue to generate interest, there are significant issues and unanswered questions regarding injector design, flame stabilization, wall heat transfer, CO emissions, combustion dynamics and other combustion phenomenon. For natural gas, direct-fired cycles with carbon capture it is believed that Computational Fluid Dynamics (CFD) modeling will play an essential role in the combustor design process. To accurately model turbulent reacting flows at these unique conditions, experimental data is needed to validate CFD codes and sub-models and is currently lacking at conditions relevant for these cycles. This paper presents the conceptual design and CFD simulations of an experimental 80 bar oxy-combustion facility and test article currently under construction at NETL. The facility is targeted towards the testing of a single injector, direct-fired sCO2 combustor at the 100 kW thermal output level. While these conditions do not reflect the actual Allam cycle operating conditions (300 bar) they are viewed as a stepping stone in the model validation process at supercritical conditions. Reynolds Averaged Navier-Stokes as well as Large Eddy Simulation are used to model the turbulent combustion process and aid in the design of the combustor and injector. Process parameters including oxidizer preheat temperature and combustor flowrate are investigated.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2021

Studies of Alternative Ventilation Configurations to Mitigate Airborne Exposure Risks in Office Spaces

The objective of this study was to evaluate the impact of alternative ventilation configurations on airflow patterns and potential exposure risks in office spaces. Two existing conference rooms at Sandia NM were modeled using Computational Fluid Dynamics (CFD) simulations to characterize airflow patterns and potential airborne exposure risks in well-mixed and once-through (through-flow) ventilation conditions. Multiple scenarios were studied to evaluate the impact of occupancy, Plexiglass barriers, and a modified-return airflow configuration. Experimental and visualization tests were also conducted to validate the well-mixed and through-flow models and findings. The simulations demonstrated that the modified-return airflow configuration that promoted through-flow conditions reduced pathogen concentrations within the space compared to the well-mixed airflow configuration; occupancy reduction only reduced the number of exposed individuals, and Plexiglass barriers had almost no effect. The experimentally measured air speeds at nine anemometer locations generally matched the simulated airflow velocities, and a fog-purge visualization test was also consistent with simulated results of plume movement and dissipation. The visualization tests demonstrated improvements in air change rate with the modified return, which promoted through-flow conditions, versus the original well-mixed ventilation configuration. The results of this study demonstrate that minor modifications to a space that promote through-flow conditions can improve air quality and reduce pathogen concentrations. Additional airflow modeling and testing of alternative occupied space configurations are recommended to further inform room designs that mitigate airborne exposure risks for occupants.

42 ENGINEERING↗
DOE OSTI2022

NorthStar Facility Target Fab and Flow Testing - FY 21

The facility target fabrication and flow testing activity will consist of flow tests using the blower system at LANL to test the disk holder and target, both redesigned by the NorthStar prime contractor. The housing and transition system delivering helium cooling to the disc holder and target will be fabricated and tested at LANL facilities. The tests will include pressure drop versus flow measurements through the target and housing, optical flow diagnostics and fiber optic imaging of the disc stack. The pressure drop measurements will be compared to CFD simulations to verify the latter, the optical flow diagnostics will be used to determine whether modifications made to the housing and target holder allow sufficient flow through the bottom of the housing to adequately cool it and the fiber optics will be used to image the discs during operation as a proof of concept of the diagnostic, to be used at NorthStar facilities during preproduction testing. The work is a Partial Fulfillment of the Deliverable Requirement for NorthStar Facility Target Fab and Flow Testing and Production Target Testing Support by LANL

42 ENGINEERING↗
DOE OSTI2022

Completion of initial reduced-order model for flammable refrigerant dispersal in residential spaces

Environmental regulations aimed at reducing global warming impacts of HVAC&R refrigerants have resulted in the phase-out of chlorofluorocarbons (CFCs) in 2010 and hydrochlorofluorocarbons (HCFCs) by 2030 in developed countries with additional restrictions on the use of hydrofluorocarbons (HFCs) set to take effect in 2036. Many of the remaining alternative refrigerants that have lower global warming potential (GWP) and that are suitable for use in HVAC&R systems (e.g., propane, difluoromethane) are flammable to some degree. Flammable refrigerants introduce new challenges and hazards to property and personal safety related to potential deflagration during system maintenance or due to leakage of the refrigerant accumulating in the conditioned space. Standards have been developed to set maximum charge limits for flammable refrigerants in HVAC&R systems; however, existing safety standards and codes still restrict their use. The bodies that maintain and update these codes need publicly available, science-based information to enable credible guidelines for setting safe charge limits for different flammable refrigerants in different HVAC&R applications. In 2016, the Alliance for Responsible Atmospheric Policy, the Air-Conditioning Heating and Refrigeration Institute (AHRI), ASHRAE, the U.S. Department of Energy (DOE), and the State of California began efforts to develop such information. As part of this effort, Oak Ridge National Laboratory (ORNL) began the current, ongoing project to examine imposed charge limits for flammable refrigerants and identify reasonable adjustments to these limits when found appropriate. Past tasks under this project have included development of experimentally vetted, computational fluid dynamics (CFD) simulation approaches to study the results of leakage of flammable refrigerants from various HVAC&R systems into different types of commercial and residential spaces. In this report, we discuss recent efforts to develop a predictive model of the flammable volume fraction and accumulated refrigerant mass in a single-room residential space resulting from the leak of a flammable refrigerant from a small room air conditioning (RAC) unit. The eventual goal is development of a model suitable for public release which could simulate a range of scenarios. In discussions with the AHRTI Flammable Refrigerant Subcommittee (FRS) at the beginning of this effort, a total of 9 input parameters were chosen for consideration including room area, room/door opening area, ventilation fan flow rate, unit/leak height, leak area, leak rate, total refrigerant charge, refrigerant molecular weight, and state of the unit fan.

42 ENGINEERING↗
DOE OSTI2023

Nanosecond Repetitively Pulsed (NRP) Plasmas: Relationship Between Induced Flow and Plasma Characteristics at Atmospheric Pressure (Final Technical Report)

The local flow fields induced by plasma discharges at atmospheric pressure can play a critical role in aerodynamic flow and combustion control and have significant implications for plasma-based technologies in medicine and environmental engineering. However, the coupling between the plasma characteristics, the geometry and the induced flow field is not well understood. The primary goal of this work is to determine the relationship between the plasma characteristics and the induced flow field for nanosecond pulsed discharges at atmospheric pressure. A comprehensive experimental investigation of plasmas produced by nanosecond high-voltage pulses in a pin-to-pin electrode configuration was conducted, employing several measurement techniques including microwave and laser Rayleigh scattering, optical emission spectroscopy, and high-speed imaging. The flow field induced by the nanosecond plasma was measured and characterized using measurements of the velocity (particle image velocimetry) and density (background oriented schlieren) with unprecedented spatiotemporal resolution. The experimental measurements were complemented by development of a one-dimensional model of the plasma discharge and a high-fidelity computational fluid dynamics (CFD) simulation of the subsequent plasma-induced flow field.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Cummins R-SOFC System Development

The overall purpose of this project was to reduce the Reversible-Solid Oxide Fuel Cell (R-SOFC) system cost by developing two technologies, an improved cell design and the incorporation of an ejector in the fuel recycle loop instead of a blower. A Simulink model of the baseline SOFC system was developed and calibrated with experimental test data. The R-SOFC system model was built by integrating GT Suite developed models of the steam generation components into the baseline Simulink SOFC system model. The ability to run the stack in SOEC operating mode was also added to the model. The system model was used to explore the ability of the R-SOFC system to meet operational constraints on Steam/Carbon ratio and H2 concentration on the fuel side electrode. A CFD ejector model was developed and used to explore a range of ejector design parameters, leading to the final ejector design that was prototyped for testing. A prototype steam ejector was first tested in a laboratory environment using room temperature air. The steam ejector was subsequently tested using the full hot recycle loop with all relevant heat exchangers and steam generation components. The test conditions utilized temperatures, pressures, and flow rates expected in an R-SOFC application. Throughout the experimental testing work, ejector performance test data was used to improve and then validate the CFD ejector model. A CFD cell model was developed and used to optimize thermal gradients, voltage, and cost of a new cell substrate design. A CFD comparison of co-flow and cross-flow cell designs informed the decision to use a co-flow design for the new cell substrate. Multiple rounds of CFD simulation were used to improve the cell design to minimize the variation in air and fuel distribution across cell channels and to minimize the variation in air and fuel distribution across different cells in the stack. A few prototypes of the new cell substrate design were produced and validated in a laboratory environment by thermally spraying and verifying that they met established manufacturing specifications. The cell manufacturing process was adjusted in order to bring these metrics within acceptable tolerances. Cummins’ internal calculations show that the new cell design reduces cost ~50% compared to the baseline cell, while the ejector + superheater/boiler concept reduces cost of the recycle loop by ~40%. The impact of these cost reductions on the cost of producing H2 will depend on the specific system where they are applied. Therefore, a Techno-Economic Analysis was completed using system cost as a variable, and showing how the NREL Current and Future system costs translate into H2 production cost.

Henrichsen, Lars↗
DOE OSTI2024

Testing of Helium-Cooled Metal Molybdenum Disk Target

NorthStar Medical Radioisotopes LLC is planning to produce an important medical radioisotope, molybdenum-99 (Mo-99), through photonuclear reaction on molybdenum-100 (Mo-100). In this approach, molybdenum metal will be bombarded with a 40-MeV electron beam. Because enriched Mo-100 is expensive, it is desired to use as much beam power as possible to achieve maximum production yield and minimize target mass. This objective leads to very high beam power density (heat deposition in the target), which sets challenging requirements for cooling. Together with scientists at Los Alamos National Laboratory, a team at Argonne National Laboratory has developed and demonstrated a cooling approach using pressurized helium, which allows for efficient heat removal. One of the main challenges in this approach is the management of the heat load on the target window. The target window separates the high-pressure helium inside the target from the vacuum in the beamline, so it is constantly under stress from differential pressure. Also, the window is cooled only by the helium gas flowing on one side, making the window cooling even more challenging. High heat deposition in the target disks also imposes a strict requirement on performance of the helium cooling system and thickness of the target disks. The target disks are produced from metal powder via a press-and-sinter process. The resulting disks do not possess tensile strength as high as solid molybdenum and might not survive the vibration from the high-velocity helium coolant and high thermal stress from beam heating. An Argonne team of scientists performed a series of tests at Argonne’s Low Energy Accelerator Facility (LEAF) [3-7]. This report describes two series of tests for scale down production target designs that utilize full-scale 29 millimeters diameter, 0.75 mm thick press-and-sintered disks. We performed two thermal tests with different beam parameters and configurations of the disk laminations. We compared the results of the window temperature measurements and cooling system parameters obtained in the experiments with those predicted by analytical calculations and Computation Flow Dynamic (CFD) simulations. Results of the experiments and calculations are presented below.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Carbon Capture through Membranes - Leveraging Multiphysics Modeling, Dimensional Analysis and Machine Learning to Scale up and Optimize Devices and Processes for Decarbonization

We study the separation performance using membrane modules through dimensional analysis (DA). We formulate the main process equations to identify relevant dimensionless numbers inherent in the physics. In particular, we identify that the critical step in the separation process is mass transfer through the selective layer. Remarkably, the dimensionless feed flow (DFfeed) emerges as a crucial factor in describing this process. Not only does DFfeed directly appear in the governing equations, but it also holds a physical significance associated with the time scales for the mass transfer across the feed side and through the selective layer. Regarding the output performance variables, we consider the recovery, stage cut, productivity and purity. In this context, we profit from experimental data and CFD simulations to evaluate the separation performance of the modules when varying the input flowrate, the scale of the module, and the CO2 permeance. These datasets enable us to establish correlations between performance metrics and the dimensionless feed flow (DFfeed). Using simple power functions of DFfeed, we obtain R2 coefficients exceeding 0.99, indicating the accuracy of the correlations built in the present work. In the future, we wish to use DA to understand key transport mechanisms, predict and control module performance, and challenge the universality of these findings by testing various gas separations across different membrane modules beyond our case study.

Pedrozo, Hector A.↗
DOE OSTI2023

SAF Combustion & Soot Processes [Slides]

The atomization, mixing, combustion and emissions characteristics of aviation fuels were measured using a novel approach based on a non-continuous injection scheme called the single-hole atomizer (SHA). High-speed microscopy revealed differences between fuels in terms of evaporation and mixing regimes over conditions relevant to modern and next generation aero-engine combustors. Measurements of liquid and vapor penetration, mixing fields, combustion and emissions metrics (ignition delay, lift-off length, PAH formation, soot mass) highlighted the effects of fuels and combustor conditions. The experimental results are being leveraged to adjust and validate chemical and CFD models. Detailed analysis of sampled soot showed subtle differences in soot morphology between fuels. The results revealed the presence of contaminants potentially affecting surface chemistry and the nucleation propensity of water droplets on particles. Chemical mechanisms for NJFCP A-2, C-1 and C-4 showed good performance over a large parameter space. Spray breakup at relight conditions is vastly different from the atomization observed at high pressure. CFD simulations of the SHA target conditions confirmed the good behavior of the C-1 kinetic mechanism. The simulations support the strong relationship between low and high temperature reactions. New altitude chamber facility to enable detailed characterization of the heterogeneous nucleation process of water on aerosol particles.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

MFiX: Fractional-Step Method Implementation

A comprehensive, multiphase computational fluid dynamics (CFD) simulation solves several coupled transport equations including continuity, momentum, species, and energy. Chemical reactions further couple these equations through heats of reaction and rates of formation of products and rates of destruction of reactants. A fractional-step method separates changes attributed to chemical reactions from transport phenomena like convection and diffusion. When the governing equations are split into the transport and reacting components, efficient and independent methodologies can be exploited to solve the different systems. Specifically, discretization of field variable transport equations results in large, sparse matrices which are loosely coupled. These systems are solved in succession using iterative techniques that take advantage of the matrix structure. In contrast, chemical reactions tightly couple field variables locally within the domain (e.g., within a single computational cell) resulting in low dimensional but dense, nonlinear systems that are better solved using direct integration techniques.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Modeling and Scaling up of Membrane Modules Leveraging Dimensional Analysis

In the current analysis, we study the separation performance using membrane modules through dimensional analysis (DA). We formulate the main process equations to identify relevant dimensionless numbers inherent in the physics. In particular, we identify that the critical step in the separation process is mass transfer through the selective layer. Remarkably, the dimensionless feed flow (DFfeed) emerges as a crucial factor in describing this process. Not only does DFfeed directly appear in the governing equations, but it also holds a physical significance associated with the time scales for the mass transfer across the feed side and through the selective layer. Regarding the output performance variables, we consider the recovery, stage cut, productivity and purity. In this context, we profit from experimental data and CFD simulations to evaluate the separation performance of the modules when varying the input flowrate, the scale of the module, and the CO2 permeance. These datasets enable us to establish correlations between performance metrics and the dimensionless feed flow. Using simple power functions of DFfeed, we obtain R2 coefficients exceeding 0.99, indicating the accuracy of the correlations built in the present work. In the future, we wish to use DA to understand key transport mechanisms, predict and control module performance, and challenge the universality of these findings by testing various gas separations across different membrane modules beyond our case study.

Pedrozo, Hector A.↗
DOE OSTI2024

Computational Analysis of the Effect of Structured Packing Design on Absorption Column Hydrodynamics for Post-Combustion Carbon Capture Applications

Solvent based post-combustion carbon capture technologies have a potential for reducing carbon emissions from fossil-fuel-fired power plants and industrial sources where CO2 emissions are inherently harder to mitigate, such as steel or cement industries. A prominent technology to achieve this is by retrofitting absorption columns to the existing infrastructure. While these systems have been among the less costly alternatives for carbon capture, they still impose a considerable energy penalty to the operation of power plants or industrial facilities. The optimization of CO2 capture rate in solvent-based absorption process is complex as it depends on several factors including CO2 solubility, solvent reaction kinetics and temperature effects on the solubility, reaction rates, surface tension, and thermophysical properties of the solvent and the flue gas. The overall heat and mass transfer also depends on the hydrodynamics, which in turn, is affected by the packing geometry. In the current work, we systematically quantify the effects the design of the structured packing has on the column hydrodynamics, by performing detailed CFD simulations for different geometrical configurations and operating conditions. We then obtain relationships between the key hydrodynamic metrics, such as liquid holdup, interfacial area, wetted area, and pressure drop to the parameters defining the packing geometries and identify new more effective packing designs for the given operating conditions.

Shah, Yash Girish↗
DOE OSTI2025

INTEGRATE – Inverse Network Transformations for Efficient Generation of Robust Airfoil and Turbine Enhancements

The INTEGRATE (Inverse Network Transformations for Efficient Generation of Robust Airfoil and Turbine Enhancements) project developed a new inverse-design capability for the aerodynamic design of wind turbine rotors using invertible neural networks. Training data was obtained from improved turbulence and transition models for RANS and hybrid RANS/LES solvers with machine-learned physics-based data-augmented corrections and then using the resulting neural-network(s) augmented RANS model to run thousands of 2-D and 3-D CFD simulations.

17 WIND ENERGY↗
DOE OSTI2023

Rapid CFD Using Machine Learning Algorithms (CRADA Final Report)

This is a collaborative effort between Lawrence Livermore National Security, LLC as manager and operator of Lawrence Livermore National Laboratory (“LLNL”) and Guardian Glass, LLC ("Guardian Glass") to develop a fast-running emulator of the reactive Computational Fluid Dynamics (“CFD”) simulations needed to understand the complex reactions and flows in the glass melting, fining, and forming subprocesses. This CRADA project is sponsored under the High-Performance Computing for Manufacturing (“HPC4Mfg”) Program of the Department of Energy’s Advanced Manufacturing Office (“AMO”) within the Energy Efficiency and Renewable Energy (“EERE”) Office.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Plasma-Assisted Pre-Chamber Ignition System for Highly Dilute Stoichiometric Heavy-Duty Natural Gas Engines (Final Technical Report)

This project explored advanced ignition technologies to significantly enhance efficiency and reduce operating costs for heavy-duty natural gas engines operating at stoichiometric conditions, while meeting ultra-low NOx emission standards. The main goal was to develop and validate a plasma-assisted pre-chamber ignition system that could deliver at least a 2% increase in brake thermal efficiency (BTE) and a 4% decrease in total cost of ownership (TCO) compared to a typical multi-cylinder engine with three-way catalyst aftertreatment, ensuring compatibility with the expected 2027 EPA/CARB regulations. In the first half of the project, the research team concentrated on developing and testing plasma-assisted pre-chamber ignition using nanosecond pulsed discharges. Extensive experiments were conducted in an optically accessible rapid-compression and expansion machine, a constant-volume chamber, and an optical single-cylinder engine. Experiments were coupled with CFD simulations. The work produced unique insights into pre-chamber flame formation, jet ignition, dilution effects, and flame quenching at pressures, temperatures, and dilution levels relevant to engines. Although plasma-assisted ignition showed promise in controlled lab settings, the research also identified fundamental and practical challenges when applying this technology to real engine conditions. Midway through the project, a crucial pivot was made, guided by three key findings. First, the power electronics required for nanosecond plasma discharges were found to be too costly for commercial use, undermining the project’s cost-of-ownership goals. Second, nanosecond plasma ignition was highly sensitive to turbulent flow in the pre-chamber, resulting in lower ignition reliability than traditional spark under engine-like conditions. Third, achieving a truly diffuse low-temperature plasma at high pressures near top dead center was not possible, reducing the anticipated chemical enhancement benefits. These results collectively suggested that continuing with plasma-assisted ignition was unlikely to meet both efficiency and cost objectives. In response, the project shifted focus to a more realistic approach: enhancing traditional spark-based pre-chamber ignition with significantly less spark energy. Using insights gained earlier in the project, the team redesigned the pre-chamber to maintain high dilution tolerance and quick combustion, even with lower ignition energy. Testing confirmed that with optimized pre-chamber design and combustion timing, a lower-energy spark could reliably ignite highly diluted stoichiometric mixtures, reduce burn time, and boost thermal efficiency. Final engine testing and techno-economic analysis verified that this revised approach successfully achieved the project goals. The optimized pre-chamber ignition system provided over a 2% increase in calculated brake thermal efficiency compared to the baseline engine. Notably, the lower ignition energy and simplified hardware reduced component stress, extended maintenance intervals, and lowered the total cost of ownership. When used with stoichiometric operation and traditional three-way aftertreatment, the system remained compatible with near-zero NOx emissions targets without increasing cost or complexity in the emissions control system. In summary, although the project deviated from its initial plasma-assisted ignition idea, the work produced a more practical and commercially viable solution. The results show that precisely optimized, low-energy pre-chamber spark ignition can significantly improve efficiency and reduce overall ownership costs for heavy-duty natural gas engines. This directly aligns with DOE goals for cleaner, more efficient, and cost-effective transportation technologies.

03 NATURAL GAS↗
DOE OSTI2021

Parametric Evaluation of RDE Inlet Performance using a Reduced-Order Model

This paper presents the results of a parametric study on the effects of inlet restriction, along with a number of other controlling parameters, using a previously developed reduced-order RDE inlet model. The results of this study will be used to inform subsequent high-fidelity CFD simulations and/or selection of experimental operating conditions which may be conducive to maximizing performance.

Bedick, Clinton↗
DOE OSTI2022

Design-Space Exploration for Inverse-Design of Wind Turbine Blades Using Data-Driven Methods

The state-of-the-practice aerodynamic design methods for wind turbine blades is typically based on Blade-Element Momentum (BEM) theory using a pre-designed frozen family of airfoils. The airfoils are themselves typically designed using panel methods. The design of the next-generation of large flexible rotors will need to capture the non-linear aerodynamics and three-dimensional flow to reduce the levelized cost of wind energy. Data-driven methods for aerodynamic design using data generated by computational fluid dynamics offer an attractive alternative to BEM-based methods that captures the non-linear aerodynamics of the component airfoils as well as the root and tip sections. In this work, we develop and demonstrate a framework to "smartly" explore the relevant design space in combination with an appropriate automated CFD pipeline to evaluate the aerodynamics of each design. The design-space exploration framework uses appropriate perturbations to the airfoil shape and induction profile from a baseline shape in combination with the inverse-design using BEM. The resulting designs are evaluated using an automated CFD pipeline using the in-house CFD solver framework "Mercury". We perform verification and validation to establish the capability of the Mercury framework to predict the aerodynamic performance of wind turbines. The CFD simulation of the perturbed blade shapes are optimized to restart from the converged baseline simulation to reduce the computational time. Finally, we demonstrate the design-space exploration technique for the design of the outboard section and the full rotor using perturbations to the shape and operating conditions of the NREL 5-MW turbine.

aerodynamic design methods↗