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NASA NTRS1980

Cogeneration Technology Alternatives Study (CTAS). Volume 6: Computer data. Part 2: Residual-fired nocogeneration process boiler

About fifty industrial processes from the largest energy consuming sectors were used as a basis for matching a similar number of energy conversion systems that are considered as candidate which can be made available by the 1985 to 2000 time period. The sectors considered included food, textiles, lumber, paper, chemicals, petroleum, glass, and primary metals. The energy conversion systems included steam and gas turbines, diesels, thermionics, stirling, closed cycle and steam injected gas turbines, and fuel cells. Fuels considered were coal, both coal and petroleum based residual and distillate liquid fuels, and low Btu gas obtained through the on site gasification of coal. Computer generated reports of the fuel consumption and savings, capital costs, economics and emissions of the cogeneration energy conversion systems (ECS's) heat and power matched to the individual industrial processes are presented. National fuel and emissions savings are also reported for each ECS assuming it alone is implemented. Two nocogeneration base cases are included: coal fired and residual fired process boilers.

Knightly, W. F.↗

DOE OSTI2025

AUTOIGNITION DELAY TIMES FOR REFORMATE GAS MIXTURES FROM METHANE GAS ENGINES

Methane slip is a prominent issue in natural gas reciprocating engines that are used in transportation and marine applications. The incomplete combustion that results in methane slip can be resolved with the introduction of hydrogen within the combustion mixture to improve methane oxidation and further enable combustion within the engine crevices where methane has previously remained unreacted. Steam methane reforming (SMR) is a common method used to produce hydrogen and can be used to design an onboard device to reduce methane slip from reciprocating engines. The development of this reformer device requires the validation of high-fidelity chemical kinetic models at the low temperatures of the crevice volumes of these engines. In this work, auto-ignition data is obtained using a shock tube at lean (φ—0.714 or λ—1.4) and stoichiometric (φ, λ = 1) equivalence ratios spanning a temperature range of 1042–1234 K at the 80-bar operating pressure of the test engine. Blends of methane, hydrogen, and reformate products from the SMR reaction are shock-heated in synthetic air, with the ignition delay time measured using an OH* chemiluminescence detector at 310 nm and a CH* detector at 430 nm. The experimental results are compared to several state-of-the-art chemical kinetic mechanisms from the literature. In general, most of the mechanisms show very good agreement with experiments at higher temperatures, with simulation results showing little deviation from experiments at lower temperatures. A sensitivity analysis was conducted, and the results reveal that the reaction H2 + CH3O2 = H + CH3O2H has a very significant role in determining low-temperature ignition delay times (IDTs) of SMR mixtures. These findings provide valuable insights into the chemical kinetics governing methane reformate combustion and contribute to the optimization of onboard reformer designs aimed at mitigating methane slip in natural gas-fueled engines.

Fraze, Matthew↗

DOE OSTI2023

Front-End Engineering and Design: Project Tundra Carbon Capture System (Final Report)

As the next phase of Project Tundra, Minnkota Power Cooperative (MPC) completed a front-end engineering and design (FEED) study to install a post-combustion CO 2 capture system (CCS) at the MPC operated (Square Butte Electric Cooperative-owned) Milton R. Young Station (MRYS) Unit 2 (MRY2), a 477-MW power plant fueled by North Dakota lignite. The project team completed the FEED with Fluor’s Econamine FG Plus℠ (EFG+) technology and is taking the next steps leading up to start of construction. Team members included FEED technical lead Fluor Enterprises (Fluor); owner’s engineer and balance of plant (BOP) engineer Burns & McDonnell (BMcD); leading carbon capture consultants (David Greeson Consulting, Hunt International Energy Services); environmental consultants (AECOM, Agora Environmental), other BOP engineering consultants (Golder Associates, Nels); cost-share funding agency, the North Dakota Industrial Commission (NDIC); and the Energy & Environmental Research Center (EERC). Project Tundra’s goal is to implement carbon capture, utilization, and storage (CCUS) in North Dakota, while preserving the use of lignite. Future options could lead to revitalizing legacy oil fields and creating a new CO 2 enhanced oil recovery (EOR) industry. The topic of this report is the FEED study for the carbon dioxide capture portion of Project Tundra. Building on the findings of a pre-FEED study for MRY2, the key deliverables contained in this FEED study are: a) design, costing, and performance data needed to commence project financing activities; b) engineering and material balances required to file for all project permits; and c) a final project schedule. Based on the results of the previous pre-FEED study, MPC and its team evaluated two options to provide the large amount of steam needed to operate the CCS: 1) installation of new natural gas package boilers and a new pipeline to supply natural gas to the facility and 2) extraction of steam from the existing MRYS steam turbine generator. The FEED study was performed using the package boilers option, as it was deemed to have the lowest technical risk, overall cost, and cost uncertainty. A key feature of the design, however, was the mixing the natural gas boilers’ flue gas with the MRY2 flue gas. This increased the size of the CCS system. This design also enabled the tie-in of Unit 1 flue gas for times when Unit 2 is offline. The CCS was designed to capture a combined 12,978 short tons per day (STPD) of CO 2 from the flue gases produced by the existing MRY Unit 2 along with flue gas produced by the new boiler package within the CCS. The 12,978 STPD CO 2 capture is achieved by normally processing 100% of the total available MRY Unit 2 flue gas (considering full load operation) and 100% of the boiler package flue gas, then removing 90% of the CO 2 available from the processed flue gas streams.

01 COAL, LIGNITE, AND PEAT↗

NASA NTRS1980

Cogeneration Technology Alternatives Study (CTAS). Volume 6: Computer data. Part 1: Coal-fired nocogeneration process boiler, section A

About fifty industrial processes from the largest energy consuming sectors were used as a basis for matching a similar number of energy conversion systems that are considered as candidate which can be made available by the 1985 to 2000 time period. The sectors considered included food, textiles, lumber, paper, chemicals, petroleum, glass, and primary metals. The energy conversion systems included steam and gas turbines, diesels, thermionics, stirling, closed cycle and steam injected gas turbines, and fuel cells. Fuels considered were coal, both coal and petroleum based residual and distillate liquid fuels, and low Btu gas obtained through the on site gasification of coal. Computer generated reports of the fuels consumption and savings, capital costs, economics and emissions of the cogeneration energy conversion systems (ECS's) heat and power matched to the individual industrial processes are presented. National fuel and emissions savings are also reported for each ECS assuming it alone is implemented. Two nocogeneration base cases are included: coal fired and residual fired process boilers.

Knightly, W. F.↗

NASA NTRS1989

Asymptotic behavior of a flat plate wake

An experimental study has been conducted to investigate the far-field, self-similar properties of a flat plate wake. A plane turbulent wake was generated at the trailing edge of a smooth splitter plate separating two legs of a Mixing Layer Wind Tunnel, with both initial boundary layers tripped. For the present study, both legs were operated at a free-steam velocity in the test section of 15 m/s, giving a Reynolds number based on wake momentum thickness of about 1750. Single profile measurements were obtained at five streamwise locations using a Pitot probe for the mean velocity measurements and a single cross-wire probe for the turbulence data, which included statistics up to third order. The mean flow data indicated a self-similar behavior beyond a streamwise distance equivalent to about 350 wake momentum thicknesses. However, the turbulence data show better collapse beyond a distance equivalent to about 500 momentum thicknesses, with all the measured peak Reynolds stresses achieving constant, asymptotic levels. The asymptotic mean flow behavior and peak primary stress levels agree well with theoretical predictions based on a constant eddy viscosity model. The present data also agree reasonably well with previous measurements, of which only one set extends into the self-similar region. Detailed comparisons with previous data are presented and discussed in this report.

Weygandt, James H.↗

DOE OSTI2018

Experience with Chemical Looping Combustion of Coal in a 200 kW Dual Fluidized Bed Reactor

The University of Utah recently commissioned a dual fluidized bed process development unit (PDU) for investigating chemical looping combustion (CLC) and chemical looping with oxygen uncoupling (CLOU) of coal. The reactors and supporting systems were sized to support at least 200 kW of coal input based on available reaction rate data. Both the air reactor and fuel reactor are circulating fluidized beds and bed material passes between the reactors via loop seals. The reactors are refractory-lined rather than electrically heated, so the system must be preheated with natural gas before chemical looping combustion can begin. Air and steam are preheated through a combination of electric heating and natural gas burners and reactor product gas flows through heat exchangers and bag houses to cool and clean the gas of particulate. As is typical with pilot-scale systems, several operational challenges were encountered as the system was brought online and operation progressed from heatup and initial testing with gaseous fuels towards full CLOU processing of coal. The system hardware and operational procedures have undergone several modifications, but the PDU can now reliably be preheated to the operating temperature and coal can be fed at the target feed rate. This paper presents the PDU, describes the procedures for evaluating carbon conversion, CO2 capture and CO2 purity, and presents initial results from chemical looping combustion of coal with non-CLOU and CLOU carriers. General experience of operating the plant and notable challenges and solutions are also presented.

Whitty, Kevin J.↗

DOE OSTI2021

POST-TEST EXAMINATIONS OF A LOCA SAMPLE FROM AN IRRADIATED HIGH-BURNUP PWR M5 FUEL ROD

A LOCA integral test with high burnup PWR M5 fuel rod was conducted in the Irradiated Fuel Examination Laboratory through the complete LOCA sequence: heating the LOCA sample to 300ºC and pressurizing the internal pressure to 8.27 MPa, heating at 5ºC/s from 300 to 1200ºC, holding in steam for 90s at 1200ºC, cooling at 3ºC/s to 800ºC, followed by water quench and rapid cooling to 100ºC. After LOCA testing, examinations, such as the fuel fragmentation analysis, burst and ballooning characterization, axial strain measurement, and microstructural examinations were performed. Metallographic examinations of an as-irradiated high burnup sample adjacent to the LOCA test sample revealed a bonding layer between the fuel and cladding. The posttest LOCA examinations indicates the corrosion layer formed during normal operations in the commercial reactor might provide a protection against the steam oxidation at high temperatures for test times performed in this work. The microstructure of the as-irradiated fuel is compared to the microstructure of the post-LOCA test fuel. Posttest LOCA examination on unirradiated post-tests Zr cladding samples was conducted, which served as baseline data for in cell testing with irradiated samples. The results obtained with irradiated PWR high burnup M5 fuel rad were compared to the LOCA test data obtained with irradiated BWR high burnup Zircaloy-2 fuel rod at Argonne national Laboratory.

Yan, Yong↗

DOE OSTI2015

Severe Accident Test Station Design Document

The purpose of the ORNL severe accident test station (SATS) is to provide a platform for evaluation of advanced fuels under projected beyond design basis accident (BDBA) conditions. The SATS delivers the capability to map the behavior of advanced fuels concepts under accident scenarios across various temperature and pressure profiles, steam and steam-hydrogen gas mixtures, and thermal shock. The overall facility will include parallel capabilities for examination of fuels and irradiated materials (in-cell) and non-irradiated materials (out-of-cell) at BDBA conditions as well as design basis accident (DBA) or loss of coolant accident (LOCA) conditions. Also, a supporting analytical infrastructure to provide the data-needs for the fuel-modeling components of the Fuel Cycle Research and Development (FCRD) program will be put in place in a parallel manner. This design report contains the information for the first, second and third phases of design and construction of the SATS. The first phase consisted of the design and construction of an out-of-cell BDBA module intended for examination of non-irradiated materials. The second phase of this work was to construct the BDBA in-cell module to test irradiated fuels and materials as well as the module for DBA (i.e. LOCA) testing out-of-cell, The third phase was to build the in-cell DBA module. The details of the design constraints and requirements for the in-cell facility have been closely captured during the deployment of the out-of-cell SATS modules to ensure effective future implementation of the in-cell modules.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

NASA NTRS1980

Cogeneration Technology Alternatives Study (CTAS). Volume 6: Computer data. Part 1: Coal-fired nocogeneration process boiler, section B

Knightly, W. F.↗

DOE OSTI2019

WISE-CASING: Frequency Domain EM Data from Cymric Oil Field, CA

Cymric oil field frequency domain electromagnetic (FEM) data with two parts of data labeled Part 1 and Part 2. Part 1 utilizes an electrical source line parallel to the receiver line, while Part 2 utilizes an electrical source line at a 75 deg angle to the receiver line. Data are plotted and compared to numerically modeled data to observe electric field response to well structure. In two configuration files are diagrams of the experiment layout.

15 GEOTHERMAL ENERGY↗

NASA NTRS1982

A regenerable solid amine CO2 concentrator for space station

A regenerable solid amine CO2 control system, which employs water vapor for desorption, is being developed for potential use on long duration space missions. During cyclic operation, CO2 is first absorbed from the cabin atmosphere onto the granular amine. Steam is then used to heat the solid amine bed and desorb the CO2. This paper describes the solid amine system operation and application to the Shuttle Orbiter, Manned Space Platform (MSP) and Space Operations Center (SOC). The importance and interplay of system performance parameters are presented together with supporting data and design characteristics.

Boehm, A. M.↗

NASA NTRS2014

In-Service Monitoring of Steam Pipe Systems at High Temperatures

A system and method for monitoring the properties of a fluid, such as water, in a steam pipe without mechanically penetrating the wall of the pipe. The system uses a piezoelectric transducer to launch an ultrasonic probe signal into the pipe. Reflected ultrasonic signals are captured in a transducer, which can be the same transducer that launched the probe signal. The reflected signals are subjected to data processing, which can include filtering, amplification, analog-to-digital conversion and autocorrelation analysis. A result is extracted which is indicative of a property of the fluid, such as a height of the condensed fluid, a cavitation of the condensed fluid, and a surface perturbation of the condensed fluid. The result can be recorded, displayed, and/or transmitted to another location. One embodiment of the system has been constructed and tested based on a general purpose programmable computer using instructions recorded in machine-readable non-volatile memory.

Bar-Cohen, Yoseph↗

NASA NTRS2016

Apparatus for and Method of Monitoring Condensed Water in Steam Pipes at High Temperature

Lih, Shyh-Shiuh↗

DOE OSTI2020

Streamlining Energy Sprawl: Assessment of Geothermal Impacts on Public Lands

Renewable energy power generation, including geothermal, solar photovoltaics (PV), and wind, can have significant land use impacts depending on the technology and the size of the facility. At the same time, innovations across these renewable technologies are working to improve plant efficiency per acre of disturbance. Through a survey of satellite imagery and other sources, this analysis reevaluates the impact of geothermal power generation and examines the variations in land use for different geothermal technologies (binary, flash, and dry steam). Geothermal operations on Bureau of Land Management (BLM) sites serve as the focus for this analysis - i.e., only active sites with federal mineral ownership for which the BLM receives royalties from power production. The results show significant variation in direct land disturbance across the operations sites and across these three geothermal technologies. Although there is variation across plants within the same geothermal technology category, dry steam plants (The Geysers) were shown to have the lowest impact, in acres per megawatt capacity and acres per gigawatt-hour generation, followed by flash steam and binary plants. Overall, direct land impacts relative to capacity and generation have declined 16-27% for facilities constructed since 2000 as compared to those constructed prior, even though most new facilities are binary plants (which traditionally had higher land disturbance). Additionally, capacity factors based on actual net production data were found to average only 50% across all operations sites, suggesting that previous estimates based on nameplate capacity only may lead to an undercounting of generation-based land disturbance metrics. Should the geothermal industry capture additional market share, improving land disturbance metrics through accurate net production and capacity data and further minimizing impacts will be increasingly important as competition over land use intensifies.

GEOTHERMAL ENERGY↗

DOE OSTI2019

Comparison of Oxidation Performance of Graphite Samples in TGA versus Vertical Furnace

Oxidation influences the working life of nuclear graphite and can impact function during or after air (or steam) ingress accidents. Temperature, gas flow, oxygen content, and dimensional constraints at the microstructural and macrostructural levels can substantially influence the oxidation rate. The nature of these constraints must be considered when attempting to extrapolate performance from experimental results to service applications, but must also be evaluated in order to compare data among disparate experimental systems. This work compares oxidation test performance from a vertical furnace system (functioning as described by ASTM D7542) with tests using a thermogravimetric analyzer (TGA) adapted to operate in an analogous manner.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

High Temperature Steam Electrolysis Process Performance and Cost Estimates - DOE Hydrogen Program AMR Presentation

Technology readiness levels (TRLs) of electrolysis systems have dramatically increased in recent years as the interest in clean hydrogen production and decarbonization of transportation, industrial and other sectors increases across the globe. This is especially true of high temperature steam electrolysis (HTSE) / solid oxide electrolysis cell (SOEC) systems which show promise of much higher system efficiencies than other more developed electrolysis technologies. This possibility of higher efficiencies of HTSE / SOEC systems has been previously assumed to be theoretically possible but in recent years it has become less theoretical and more realistic as an increasing amount of suppliers complete lab and pilot tests showing very promising results. Research in the areas of manufacturing techniques, material selection, electrode and electrolyte compositions, and balance of plant size and integration continues at a fast pace as an increasing number of suppliers both internationally and domestically become involved. The advantages of HTSE become more pronounced when HTSE is coupled with nuclear power plants (NPPs). This is because thermal energy produced by the nuclear reactor can be used in a series of heat transfer loops and heat exchangers to vaporize HTSE feedwater, which drastically improves the economics of the process. Idaho National Laboratory (INL) has been very involved in the research and modeling of HTSE systems for a number of years, in collaboration with other national laboratories, academia, and industry stakeholders both on the hydrogen production as well as the hydrogen demand side. The modeling completed over the years on a large variety of projects has led to a wealth of knowledge at INL including in the area of the technoeconomic assessment (TEA) of HTSE systems. TEAs include process modeling of the HTSE systems to calculate system energy requirements and equipment sizing, followed by estimation of capital and operating costs to enable calculation of the levelized cost of hydrogen (LCOH). The TEA work performed has produced incremental improvements and tuning of the methods, assumptions, models, and results of the analyses as well as providing some opportunities for validating these results. The purpose of this document is to record the current baseline HTSE analyses led by INL to show the current status of assumptions and costs of these systems. Given the rapid development of this technology, the variety of suppliers entering the space, and the increasing attention government and industry are giving to such systems, this document may be updated on a periodic basis with updated analysis and assumptions. This document compiles various analyses results and approaches completed over a period of years into a single document to be used as a baseline going forward. It represents what the INL HTSE analysis group assumes to be the internal best estimate of the current operation, costs, and landscape of the HTSE industry state of the art capability for current SOEC technology in an Nth-of-a-Kind (NOAK) plant, which in this study is defined as existence of the manufacturing capacity to support previous deployment of N = 100 count of 25 MWe modular HTSE blocks (with modular equipment component cost reductions specified as following a 95% learning curve). That said, this is a public document and as such so no proprietary data was used or included in this report. There may be HTSE suppliers that have performance specifications, and cost estimates, and test data that differ from the analysis presented in this document. This document is meant to be a best conservative estimate of the technology and not an absolute reference.

08 HYDROGEN↗

NASA NTRS1978

ECAS Phase I fuel cell results

This paper summarizes and discusses the fuel cell system results of Phase I of the Energy Conversion Alternatives Study (ECAS). Ten advanced electric powerplant systems for central-station baseload generation using coal were studied by NASA in ECAS. Three types of low-temperature fuel cells (solid polymer electrolyte, SPE, aqueous alkaline, and phosphoric acid) and two types of high-temperature fuel cells (molten carbonate, MC, and zirconia solid electrolyte, SE) were studied. The results indicate that (1) overall efficiency increases with fuel cell temperature, and (2) scale-up in powerplant size can produce a significant reduction in cost of electricity (COE) only when it is accompanied by utilization of waste fuel cell heat through a steam bottoming cycle and/or integration with a gasifier. For low-temperature fuel cell systems, the use of hydrogen results in the highest efficiency and lowest COE. In spite of higher efficiencies, because of higher fuel cell replacement costs integrated SE systems have higher projected COEs than do integrated MC systems. Present data indicate that life can be projected to over 30,000 hr for MC fuel cells, but data are not yet sufficient for similarly projecting SE fuel cell life expectancy.

Warshay, M.↗

NASA NTRS1991

Eccentricity effects on leakage of a brush seal at low speeds

The effects of eccentricity on brush seal leakage at low rotational speeds were investigated. Included are the leakage results for ambient temperature air and nearly saturated streams at three different rotor eccentricities at both 0 and 400 rpm. A brush seal with a nominal bore diameter of 13.647 cm. (5.3730 in.) was used. It had a radial concentric interference of 0.071 cm (0.0028 in.) and a fence height of 0.0927 cm (0.0365 in.). There were 1060 bristles per centimeter of circumference (2690 bristles per inch of circumference). Rotor eccentricities of 0.003, 0.010, 0.038, and 0.043 cm (0.001, 0.004, 0.015, and 0.017 in.) were achieved by using bushings with different offsets. The results were compared with an annular seal model (FLOWCAL) for air and to a standard labyrinth seal model for steam. The annular seal model was also compared with a bulk flow model of a concentric brush seal in air. Large eccentricities did not damage the brush seals or their Haynes 25 bristles. However, the 304 stainless steel rotor did not show wear, indicating a harder surface is needed. Only the stream data showed hysteresis and were affected by shaft rotation. The brush seal had lower leakage rates than those predicted for comparable annular and labyrinth seals (conventional) because of the large clearances those seals require to accommodate large shaft excursions.

Schlumberger, Julie A.↗