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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 271 records · Page 15
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Optimal operation of multi-plant steam district heating systems for enhanced efficiency and sustainability

Despite their crucial role in supplying heat and power to universities, industries, and healthcare facilities, many steam-based district heating systems rely on outdated control methods. Among these, multi-central plant districts are particularly challenging due to the complexities of coordinating multiple plants, optimizing load distributions, and managing system downtime. In response, new operational strategies are developed to enhance the efficiency and sustainability of steam districts while utilizing existing resources. These strategies include reducing plant operational pressure without compromising the reliable supply to buildings and optimizing load allocation across multiple plants. The load allocation considers boiler part-load efficiency, runtime, network losses, and building pressure set points, and is compared with traditional multi-boiler controls. To support this exploration, new dynamic Modelica models are developed. In addition, methods to reduce modeling complexities are incorporated, enhancing their suitability for practical applications. A holistic district-wide analysis using a real university case study demonstrates a 4.7% fuel savings by lowering boiler operational pressure from 900 kPa to 600 kPa, along with a 13.3% reduction in condensation losses across the distribution network. Furthermore, the load allocation approach results in a 13.1% reduction in fuel consumption during peak winter periods and 15.3% during shoulder periods, with corresponding decreases in carbon emissions and fuel costs. This approach can also save maintenance costs by reducing the boiler runtime by 49.6%. In conclusion, this research underscores the benefits of retrofitting aging steam district heating systems, offering immediate operational improvements by enhancing efficiency, meeting regulatory compliance, and extending infrastructure lifespans while delaying costly overhauls.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2020

Investigation of the benefits of diabatic microreactors for process intensification of the water-gas shift reaction within the steam reforming process

Presently, the steam reforming process is the largest industrial source of hydrogen. Improving its efficiency can help to reduce associated carbon emissions and hydrogen production costs. Intensifying the water-gas shift reaction using microreactors with integrated cooling is one way of achieving this. In this study, a 2-D computational model of one of these microreactors is developed, validated with experimental data, and then used to demonstrate how microreactors can enhance the conversion of the water-gas shift reaction beyond what can be achieved using conventional packed bed reactors. These results are then generalized into a full system model of the steam reforming process to demonstrate how microreactors can reduce hydrogen production costs. The results suggest that microreactors can significantly reduce the required reactor volume and catalyst loading for the water-gas shift reaction and can similarly reduce the hydrogen production costs associated with the steam reforming process.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2014

Highly Active and Stable MgAl2O4 Supported Rh and Ir Catalysts for Methane Steam Reforming: A Combined Experimental and Theoretical Study

In this work we present a combined experimental and theoretical investigation of stable MgAl2O4 spinel-supported Rh and Ir catalysts for the steam methane reforming (SMR) reaction. Firstly, catalytic performance for a series of noble metal catalysts supported on MgAl2O4 spinel was evaluated for SMR at 600-850°C. Turnover rate at 850°C follows the order: Pd > Pt > Ir > Rh > Ru > Ni. However, Rh and Ir were found to have the best combination of activity and stability for methane steam reforming in the presence of simulated biomass-derived syngas. It was found that highly dispersed ~2 nm Rh and ~1 nm Ir clusters were formed on the MgAl2O4 spinel support. Scanning Transition Electron Microscopy (STEM) images show that excellent dispersion was maintained even under challenging high temperature conditions (e.g. at 850°C in the presence of steam) while Ir and Rh catalysts supported on Al2O3 were observed to sinter at increased rates under the same conditions. These observations were further confirmed by ab initio molecular dynamics (AIMD) simulations which find that ~1 nm Rh and Ir particles (50-atom cluster) bind strongly to the MgAl2O4 surfaces via a redox process leading to a strong metal-support interaction, thus helping anchor the metal clusters and reduce the tendency to sinter. Density functional theory (DFT) calculations suggest that these supported smaller Rh and Ir particles have a lower work function than larger more bulk-like ones, which enables them to activate both water and methane more effectively than larger particles, yet have a minimal influence on the relative stability of coke precursors. In addition, theoretical mechanistic studies were used to probe the relationship between structure and reactivity. Consistent with the experimental observations, our theoretical modeling results also suggest that the small spinel-supported Ir particle catalyst is more active than the counterpart of Rh catalyst for SMR. This work was financially supported by the United States Department of Energy (DOE)’s Bioenergy Technologies Office (BETO) and performed at the Pacific Northwest National Laboratory (PNNL). PNNL is a multi-program national laboratory operated for DOE by Battelle Memorial Institute. Computing time was granted by a user proposal at the Molecular Science Computing Facility in the William R. Wiley Environmental Molecular Sciences Laboratory (EMSL) located at PNNL. Part of the computational time was provided by the National Energy Research Scientific Computing Center (NERSC).

ab initio molecular dynamics↗
DOE OSTI2019

High temperature oxidation and microstructural evolution of cold spray chromium coatings on Zircaloy-4 in steam environments

Oxidation kinetics and microstructural evolution of cold sprayed Cr coatings on Zircaloy-4 at 1130–1310 °C in flowing steam at atmospheric pressure have been studied. The study is aimed at understanding of the response of Cr coated Zr-alloy under a steam environment and high temperatures pertinent to design basis accidents (DBAs) and beyond design basis accidents (BDBAs) in light water reactors (LWRs). Surface morphology, microstructure, and phases of post-oxidation test samples were characterized using Scanning Electron Microscopy (SEM), x-ray diffraction (XRD), and Scanning Transmission Electron Microscopy (STEM). Growth kinetics of the Cr-oxide scale and interdiffusion layers between the Cr coating and the Zr-alloy substrate were quantified from cross-sectional SEM images. Cross-sectional analysis showed that the Cr coatings offered a 50 times reduction in oxidation rate over bare Zircaloy-4 in a 1310 °C steam environment. Oxidation kinetics at 1130 °C followed parabolic law (i.e., n ~ 0.5 in power law kinetics) but at 1230 °C and 1310 °C the value of n was suppressed to below 0.5 possibly due to the volatilization of Cr species at the two highest temperatures. Interdiffusion at coating/substrate interface resulted in formation of a brittle Cr 2 Zr or Zr(Fe, Cr) 2 intermetallic compound layer on the order of micrometer in thickness and scattered Cr-rich precipitates were observed well below the interface within the Zr-alloy substrate after cooling. These experimental results could provide data to LWR system simulation codes for better estimation of coping time in the event of accidents.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Hydrothermal corrosion and steam oxidation behavior comparison of UAM and conventional Zry-4

Here, hydrothermal corrosion and steam exposures on ultrasonic additively manufactured (UAM) Zircaloy-4 (Zry-4) specimens were conducted to compare to wrought Zry-4 performance in both simulated pressurized water reactor (PWR) operation (330°C, 15 MPa, <50 ppb oxygen, 500h) and representative accident conditions (100% H 2 O(g) at 700, 900, and 1100°C for up to 1h). UAM Zry-4 specimens showed 50% higher mass gain in PWR conditions and 50-80% more mass gain in steam oxidation due to internal oxidation between build layers in both cases. UAM Zry-4 in 900°C steam showed breakaway oxidation leading to sample deformation. Titanium used as an interlayer in the UAM process was detected in the substrate after the 1100°C exposure. Additional experiments to better link as-built defects to oxidation behavior are needed.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Steam generator model design parameter sensitivity study for small modular reactor system

Here, this study focuses on design parameter sensitivity studies pertaining to several Once-Through Steam Generator (OTSG) model cases both with and without a riser using python and advanced risk assessment and optimization tool, i.e. Risk Analysis Virtual Environment (RAVEN) developed at Idaho National Laboratory (INL), to support a Small Modular Reactor (SMR) system. The presented Steam Generator (SG) python-based model is a mathematical representation of a steam-generating unit for a Pressurized Water Reactor (PWR)-type SMR system, including fluid flow and heat transfer equations, models, and correlations. Design studies involve changing the model’s input design parameters (e.g., temperature, pressure, mass flow rate) to observe the resulting effects on the output of the system, such as the Heat Transfer Coefficient (HTC), Reynolds number, Nusselt number, and heat transfer performance. Sensitivity studies analyze the degree to which system output and/or desired parameters (e.g., HTC or heat transfer performance) are sensitive to changes in the input parameters. By using RAVEN, detailed design parametric sensitivity studies. Six input parameters—namely, the pressure, temperature, and mass flow rate for the inlet of the primary-side (hot fluid) and secondary-side (cold fluid) of the SG—were randomly perturbed via RAVEN’s Monte Carlo Sampler module, using uniform distributions (i.e., ±1%, ±5% and ±10 % relative changes) for 600 samples. The analysis results give valuable insights into SG system performance, and provide justification for further research and development such as optimized sensor placement, design verification, validation, and optimization.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2019

Optimal design of phase change material storage for steam production using annual simulation

A direct steam generation (DSG) solar collector can be an efficient process-heat application compared to electricity generation, and it can significantly reduce dependence on non-renewable energy sources for steam generation. Due to intermittency of the sun, thermal energy storage is required to increase the capacity factor or the yearly utilization of the system. For this study, phase change material (PCM) is used to store the heat from the steam produced in the solar collector. Sodium formate is selected as the PCM material on a cost basis. A detailed off-design analysis is carried to predict the annual performance of the system. Fins are used to enhance the thermal performance of the PCM, and an simplified method is derived to predict the required fin mass. With an increase in the number of fins, the thermal performance of the system increases significantly at design point. Furthermore the fins are expensive, so an annual simulation and techno-economic analysis is carried to calculate the optimal number of fins and other operating parameters.

14 SOLAR ENERGY↗
DOE OSTI2016

Cobalt-Based Catalysts for Ethanol Steam Reforming: An Overview

Cobalt has been extensively studied for its use as an alternative catalyst to noble metals for ethanol steam reforming. Among the many other catalyst supports tested, cerium oxide contributed significantly to the catalytic activity and stability of the Co/CeO 2 catalyst as a result of its high oxygen mobility and storage capacity. In this paper, an overview of the research conducted in our laboratory during the past decade on ethanol steam reforming using the Co/CeO 2 catalyst is presented. Here, the role of the support oxygen mobility and storage capacity of the Co/CeO 2 catalyst and how the addition of calcium to the ceria support changes the oxygen vacancies in the catalyst structure are discussed. Results from in situ characterization techniques, such as X-ray diffraction, Raman spectroscopy, X-ray absorption near edge structure, and extended X-ray absorption fine structure, are summarized, showing the evolution of the cobalt phases during synthesis, pretreatment, and ethanol steam reforming reaction. Also, how the synthesis parameters, such as synthesis method, impregnation medium, choice of cobalt precursor, support morphology, and particle size, could alter the catalytic activity and selectivity have been outlined.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2015

Steam Reforming of Ethylene Glycol over MgAl₂O₄ Supported Rh, Ni, and Co Catalysts

Steam reforming of ethylene glycol (EG) over MgAl₂O₄ supported metal (15 wt.% Ni, 5 wt.% Rh, and 15 wt.% Co) catalysts were investigated using combined experimental and theoretical methods. Compared to highly active Rh and Ni catalysts with 100% conversion, the steam reforming activity of EG over the Co catalyst is comparatively lower with only 42% conversion under the same reaction conditions (500°C, 1 atm, 119,000 h⁻¹, S/C=3.3 mol). However, CH₄ selectivity over the Co catalyst is remarkably lower. For example, by varying the gas hour space velocity (GHSV) such that complete conversion is achieved for all the catalysts, CH₄ selectivity for the Co catalyst is only 8%, which is much lower than the equilibrium CH₄ selectivity of ~ 24% obtained for both the Rh and Ni catalysts. Further studies show that varying H₂O concentration over the Co catalyst has a negligible effect on activity, thus indicating zero-order dependence on H₂O. These experimental results suggest that the supported Co catalyst is a promising EG steam reforming catalyst for high hydrogen production. To gain mechanistic insight for rationalizing the lower CH₃ selectivity observed for the Co catalyst, the initial decomposition reaction steps of ethylene glycol via C-O, O-H, C-H, and C-C bond scissions on the Rh(111), Ni(111) and Co(0001) surfaces were investigated using density functional theory (DFT) calculations. Despite the fact that the bond scission sequence in the EG decomposition on the three metal surfaces varies, which leads to different reaction intermediates, the lower CH₄ selectivity over the Co catalyst, as compared to the Rh and Ni catalysts, is primarily due to the higher barrier for CH₄ formation. The higher S/C ratio enhances the Co catalyst stability, which can be elucidated by the facile water dissociation and an alternative reaction path to remove the CH species as a coking precursor via the HCOH formation. This work was financially supported by the United States Department of Energy (DOE)’s Bioenergy Technologies Office (BETO) and performed at the Pacific Northwest National Laboratory (PNNL). PNNL is a multi-program national laboratory operated for DOE by Battelle Memorial Institute. Computing time and advanced catalyst characterization use was granted by a user proposal at the William R. Wiley Environmental Molecular Sciences Laboratory (EMSL). EMSL is a national scientific user facility sponsored by the Department of Energy’s Office of Biological and Environmental Research and located at PNNL.

cobalt↗
DOE OSTI2013

Comparative Investigation of Benzene Steam Reforming over Spinel Supported Rh and Ir Catalysts

In a combined experimental and first-principles density functional theory (DFT) study, benzene steam reforming (BSR) over MgAl 2 O 4 supported Rh and Ir catalysts was investigated. Experimentally, it has been found that both highly dispersed Rh and Ir clusters (1-2 nm) on the MgAl 2 O 4 spinel support are stable during the BSR in the temperature range of 700-850°C. Compared to the Ir/MgAl 2 O 4 catalyst, the Rh/MgAl 2 O 4 catalyst is more active with higher benzene turnover frequency and conversion. At typical steam conditions with the steam-to-carbon ratio > 12, the benzene conversion is only a weak function of the H 2 O concentration in the feed. This suggests that the initial benzene decomposition step rather than the benzene adsorption is most likely the rate-determined step in BSR over supported Rh and Ir catalysts. In order to understand the differences between the two catalysts, we followed with a comparative DFT study of initial benzene decomposition pathways over two representative model systems for each supported metal (Rh and Ir) catalysts. A periodic terrace (111) surface and an amorphous 50-atom metal cluster with a diameter of 1.0 nm were used to represent the two supported model catalysts under low and high dispersion conditions. Our DFT results show that the decreasing catalyst particle size enhances the benzene decomposition on supported Rh catalysts by lowering both C-C and C-H bond scission. The activation barriers of the C-C and the C-H bond scission decrease from 1.60 and 1.61 eV on the Rh(111) surface to 1.34 and 1.26 eV on the Rh50 cluster. For supported Ir catalysts, the decreasing particle size only affects the C-C scission. The activation barrier of the C-C scission of benzene decreases from 1.60 eV on the Ir(111) surface to 1.35 eV on the Ir50 cluster while the barriers of the C-H scission are practically the same. The experimentally measured higher BSR activity on the supported highly dispersed Rh catalyst can be rationalized by the thermodynamic limitation for the very first C-C bond scission of benzene on the small Ir50 catalyst. The C-C bond scission of benzene on the small Ir50 catalyst is highly endothermic although the barrier is competitive with the barriers of both the C-C and the C-H bond-breakings on the small Rh50 catalyst. The calculations also imply that, for the supported Rh catalysts the C-C and C-H bond scissions are competitive, independently of the Rh cluster sizes. After the initial dissociation step via either the C-C or the C-H bond scission, the C-H bond breaking seems to be more favorable rather than the C-C bond breaking on the larger Rh terrace surface. This work was financially supported by the United States Department of Energy’s Office of Biomass Program’s. Computing time was granted by a user project at the Molecular Science Computing Facility in the William R. Wiley Environmental Molecular Sciences Laboratory (EMSL), a national scientific user facility sponsored by the Department of Energy's Office of Biological and Environmental Research and located at Pacific Northwest National Laboratory.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2014

Supported metal catalysts for alcohol/sugar alcohol steam reforming

Despite extensive studies on hydrogen production via steam reforming of alcohols and sugar alcohols, catalysts typically suffer a variety of issues from poor hydrogen selectivity to rapid deactivation. Here, we summarize recent advances in fundamental understanding of functionality and structure of catalysts for alcohol/sugar alcohol steam reforming, and provide perspectives on further development required to design highly efficient steam reforming catalysts.

metal catalysts↗
DOE OSTI2014

Acoustic emission analysis on tensile failure of steam-side oxide scales formed on T22 alloy superheater tubes

Failure of steam-side oxide scales on boiler tubes can seriously influence the safety of coal-fired power plants. Uniaxial tensile tests employing acoustic emission (AE) monitoring were performed, in this work, to investigate the failure behavior of steam-side oxide scales on T22 alloy boiler superheater tubes. The characteristic frequency spectra of the captured AE signals were obtained by performing fast Fourier transform. Three distinct peak frequency bands, 100-170, 175-250, and 280-390 kHz, encountered in different testing stages were identified in the frequency spectra, which were confirmed to, respectively, correspond to substrate plastic deformation, oxide vertical cracking, and oxide spalling with the aid of scanning electronic microscopy observations, and can thus be used for distinguishing different oxide failure mechanisms. Finally, the critical cracking strain of the oxide scale and the interfacial shear strength of the oxide/substrate interface were estimated, which are the critical parameters urgently desired for modeling the failure behavior of steam-side oxide scales on boiler tubes of coal-fired power plants.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2015

Numerical solution of 2D wet steam flow with non-equilibrium condensation and real thermodynamics

An approach to modeling of wet steam flow with non-equilibrium condensation phenomenon is presented. The first part of our flow model is homogeneous Euler system of transport equations for mass, momentum and total energy of wet steam (mixture). The additional second part describes liquid phase via non-homogeneous system of transport equations for moments of droplets number distribution function and relies on corrected classical nucleation theory. Moment equations are closed by linearization of droplet growth rate model. All necessary relations for thermodynamic properties of steam are provided by IAPWS set of equations. However, properties of condensate are simply modeled by liquid saturation data. Two real equations of state are implemented. Recently developed CFD formulation for entropy (does not require iteration process) and so-called IAPWS special gas equation for Helmholtz energy (one iteration loop is necessary). Flow model is validated on converging-diverging supersonic nozzle with Barschdorff geometry. Simulations were performed by in-house CFD code based on finite volume method and stiff character of equations was solved by symmetrical time operator splitting. Achieved results satisfactorily agreed with experimental data.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2023

Infrared thermometry in high temperature materials processing: influence of liquid water and steam

Here, the capability of four infrared thermometry techniques (2-colour and 1-colour pyrometers, Pyrolaser and IR camera) was evaluated with respect to the impact of water or steam in the line of sight to determine temperature from two heat sources (blackbody calibration source and steel block inside the furnace). The influence of liquid water on the temperature readings was minimal when using 2-colour pyrometry due to comparable absorption coefficients of water for the measured wavelengths. The signals measured using both the Pyrolaser and the 1-colour pyrometer were decreased due to the partial absorption and resulted in an apparent temperature lower than the actual. Water readily absorbed the IR signal in the range of the IR camera operation, resulting in no signal whenever liquid water was present in the line of sight. Steam caused the most deviation and fluctuation of temperature readings for all techniques due to the large level of light scattering in addition to the absorption of the radiant energy. A technique was developed to determine the transmissivity (apparent emissivity) when water or steam is in the line of sight of measurement. An approximate correction to the measurements based on Planck’s law is discussed for both 2-colour and 1-colour pyrometers.

2-colour and 1-colour pyrometry↗
DOE OSTI2016

A separate phase drag model and a surrogate approximation for simulation of the steam assisted gravity drainage (SAGD) process

General ensemble phase averaged equations for multiphase flows have been specialized for the simulation of the steam assisted gravity drainage (SAGD) process. In the average momentum equation, fluid-solid and fluid-fluid viscous interactions are represented by separate force terms. This equation has a form similar to that of Darcy’s law for multiphase flow but augmented by the fluid-fluid viscous forces. Models for these fluid-fluid interactions are suggested and implemented into the numerical code CartaBlanca. Numerical results indicate that the model captures the main features of the multiphase flow in the SAGD process, but the detailed features, such as plumes are missed. We find that viscous coupling among the fluid phases is important. Advection time scales for the different fluids differ by several orders of magnitude because of vast viscosity differences. Numerically resolving all of these time scales is time consuming. To address this problem, we introduce a steam surrogate approximation to increase the steam advection time scale, while keeping the mass and energy fluxes well approximated. This approximation leads to about a 40-fold speed-up in execution speed of the numerical calculations at the cost of a few percent error in the relevant quantities.

02 PETROLEUM↗
DOE OSTI2012

High Temperature and Pressure Steam-H 2 Interaction with Candidate Advanced LWR Fuel Claddings

This report summarizes the work completed to evaluate cladding materials that could serve as improvements to Zircaloy in terms of accident tolerance. This testing involved oxidation resistance to steam or H 2 -50% steam environments at 800-1350°C at 1-20 bar for short times. A selection of conventional alloys, SiC-based ceramics and model alloys were used to explore a wide range of materials options and provide guidance for future materials development work. Typically, the SiC-based ceramic materials, alumina-forming alloys and Fe-Cr alloys with ≥25% Cr showed the best potential for oxidation resistance at ≥1200°C. At 1350°C, FeCrAl alloys and SiC remained oxidation resistant in steam. Conventional austenitic steels do not have sufficient oxidation resistance with only ≈18Cr-10Ni. Higher alloyed type 310 stainless steel is protective but Ni is not a desirable alloy addition for this application and high Cr contents raise concern about α' formation. Higher pressures (up to 20.7 bar) and H 2 additions appeared to have a limited effect on the oxidation behavior of the most oxidation resistant alloys but higher pressures accelerated the maximum metal loss for less oxidation resistant steels and less metal loss was observed in a H 2 -50%H 2 O environment at 10.3 bar. As some of the results regarding low-alloyed FeCrAl and Fe-Cr alloys were unexpected, further work is needed to fundamentally understand the minimum Cr and Al alloy contents needed for protective behavior in these environments in order to assist in alloy selection and guide alloy development.

36 MATERIALS SCIENCE↗
DOE OSTI2015

Steam Oxidation of FeCrAl and SiC in the Severe Accident Test Station (SATS)

Numerous research projects are directed towards developing accident tolerant fuel (ATF) concepts that will enhance safety margins in light water reactors (LWR) during severe accident scenarios. In the U.S. program, the high temperature steam oxidation performance of ATF solutions has been evaluated in the Severe Accident Test Station (SATS) at Oak Ridge National Laboratory (ORNL) since 2012 and this facility continues to support those efforts in the ATF community. Compared to the current UO 2 /Zr-based alloy fuel system, alternative cladding materials can offer slower oxidation kinetics and a smaller enthalpy of oxidation that can significantly reduce the rate of heat and hydrogen generation in the core during a coolant-limited severe accident. Thus, steam oxidation behavior is a key aspect of the evaluation of ATF concepts. This report summarizes recent work to measure steam oxidation kinetics of FeCrAl and SiC specimens in the SATS.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2016

BWR Steam Dryer Alternating Stress Assessment Procedures

This report presents an overview of Boiling Water Reactor (BWR) steam dryer design; the fatigue cracking failures that occurred at the Quad Cities (QC) plants and their root causes; a history of BWR Extended Power Uprates (EPUs) in the USA; and a discussion of steam dryer modifications/replacements, alternating stress mechanisms on steam dryers, and structural integrity evaluations (static and alternating stress).

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗