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All sources NASA NTRS DOE OSTI

NASA NTRS1980

Coal gasification systems engineering and analysis. Appendix B: Medium B+U gas design

A four module, 20,000 TPD, based on KT coal gasification technology was designed. The plant processes Kentucky No. 9 coal with provisions for up to five percent North Alabama coal. Medium BTU gas with heat content of 305 BTU/SCF and not more than 200 ppm sulfur is the primary plant product. Sulfur is recovered for scale as prilled sulfur. Ash disposal is on site. The plant is designed for zero water discharge. Trade studies provided the basis for not using boiler produced steam to drive prime movers. Thus process derived steam in excess of process requirements in superheated for power use in prime movers. Electricity from the TVA grid is used to supply the balance of the plant prime mover power requirements. A study of the effect of mine mouth coal cleaning showed that coal cleaning is not an economically preferred route. The design procedure involved defining available processes to meet the requirements of each system, technical/economic trade studies to select the preferred processes, and engineering design and flow sheet development for each module. Cost studies assumed a staggered construction schedule for the four modules beginning spring 1981 and a 90% on stream factor.

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NASA NTRS1976

Energy Conversion Alternatives Study (ECAS), Westinghouse phase 1. Volume 7: Metal vapor Rankine topping-steam bottoming cycles

Adding a metal vapor Rankine topper to a steam cycle was studied as a way to increase the mean temperature at which heat is added to the cycle to raise the efficiency of an electric power plant. Potassium and cesium topping fluids were considered. Pressurized fluidized bed or pressurized (with an integrated low-Btu gasifier) boilers were assumed. Included in the cycles was a pressurizing gas turbine with its associated recuperator, and a gas economizer and feedwater heater. One of the ternary systems studied shows plant efficiency of 42.3% with a plant capitalization of $66.7/kW and a cost of electricity of 8.19 mills/MJ (29.5 mills/kWh).

Deegan, P. B.↗

NASA NTRS1977

Thermal energy storage heat exchanger: Molten salt heat exchanger design for utility power plants

The use of thermal energy storage (TES) in the latent heat of molten salts as a means of conserving fossil fuels and lowering the cost of electric power was evaluated. Public utility systems provided electric power on demand. This demand is generally maximum during late weekday afternoons, with considerably lower overnight and weekend loads. Typically, the average demand is only 60% to 80% of peak load. As peak load increases, the present practice is to purchase power from other grid facilities or to bring older less efficient fossil-fuel plants on line which increase the cost of electric power. The widespread use of oil-fired boilers, gas turbine and diesel equipment to meet peaking loads depletes our oil-based energy resources. Heat exchangers utilizing molten salts can be used to level the energy consumption curve. The study begins with a demand analysis and the consideration of several existing modern fossil-fuel and nuclear power plants for use as models. Salts are evaluated for thermodynamic, economic, corrosive, and safety characteristics. Heat exchanger concepts are explored and heat exchanger designs are conceived. Finally, the economics of TES conversions in existing plants and new construction is analyzed. The study concluded that TES is feasible in electric power generation. Substantial data are presented for TES design, and reference material for further investigation of techniques is included.

Ferarra, A.↗

NASA NTRS2003

Thermographic Inspections Save Skins and Prevent Blackouts

Scanning thermography involves heating a component s surface and subsequently measuring the surface temperature, using an infrared camera to identify structural defects such as corrosion and disbonding. It is a completely noninvasive and noncontacting process. Scans can detect defects in conventional metals and plastics, as well as in bonded aluminum composites, plastic- and resinbased composites, and laminated structures. The apparatus used for scanning is highly portable and can cover the surface of a test material up to six times faster than conventional thermography. NASA scientists affirm that the technology is an invaluable asset to the airlines, detecting potential defects that can cause structural failure.In 1996, ThermTech Services, Inc., of Stuart, Florida, approached NASA in an effort to evaluate the technology for application in the power and process industries, where corrosion is of serious concern. ThermTech Services proceeded to develop the application for inspecting boiler waterwall tubing at fossil-fueled electric-generating stations. In 1999, ThermTech purchased the rights to NASA s patented technology and developed the specialized equipment required to apply the inspecting method to power plant components. The ThermTech robotic system using NASA technology has proved to be extremely successful and cost effective in performing detailed inspections of large structures such as boiler waterwalls and aboveground chemical storage tanks. It is capable of inspecting a waterwall, tank-wall, or other large surfaces at a rate of approximately 10 square feet per minute or faster.

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NASA NTRS1980

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

Various advanced energy conversion systems (ECS) are compared with each other and with current technology systems for their savings in fuel energy, costs, and emissions in individual plants and on a national level. 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 candidates 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 for coal fired process boilers. National fuel and emissions savings are also reported for each ECS assuming it alone is implemented.

Knightly, W. F.↗

NASA NTRS1981

Assessment of disk MHD generators for a base load powerplant

Results from a study of the disk MHD generator are presented. Both open and closed cycle disk systems were investigated. Costing of the open cycle disk components (nozzle, channel, diffuser, radiant boiler, magnet and power management) was done. However, no detailed costing was done for the closed cycle systems. Preliminary plant design for the open cycle systems was also completed. Based on the system study results, an economic assessment of the open cycle systems is presented. Costs of the open cycle disk conponents are less than comparable linear generator components. Also, costs of electricity for the open cycle disk systems are competitive with comparable linear systems. Advantages of the disk design simplicity are considered. Improvements in the channel availability or a reduction in the channel lifetime requirement are possible as a result of the disk design.

Chubb, D. L.↗

NASA NTRS1993

Second law analysis of a conventional steam power plant

A numerical investigation of exergy destroyed by operation of a conventional steam power plant is computed via an exergy cascade. An order of magnitude analysis shows that exergy destruction is dominated by combustion and heat transfer across temperature differences inside the boiler, and conversion of energy entering the turbine/generator sets from thermal to electrical. Combustion and heat transfer inside the boiler accounts for 53.83 percent of the total exergy destruction. Converting thermal energy into electrical energy is responsible for 41.34 percent of the total exergy destruction. Heat transfer across the condenser accounts for 2.89 percent of the total exergy destruction. Fluid flow with friction is responsible for 0.50 percent of the total exergy destruction. The boiler feed pump turbine accounts for 0.25 percent of the total exergy destruction. Fluid flow mixing is responsible for 0.23 percent of the total exergy destruction. Other equipment including gland steam condenser, drain cooler, deaerator and heat exchangers are, in the aggregate, responsible for less than one percent of the total exergy destruction. An energy analysis is also given for comparison of exergy cascade to energy cascade. Efficiencies based on both the first law and second law of thermodynamics are calculated for a number of components and for the plant. The results show that high first law efficiency does not mean high second law efficiency. Therefore, the second law analysis has been proven to be a more powerful tool in pinpointing real losses. The procedure used to determine total exergy destruction and second law efficiency can be used in a conceptual design and parametric study to evaluate the performance of other steam power plants and other thermal systems.

Liu, Geng↗

NASA NTRS1992

Active magnetic bearings: As applied to centrifugal pumps

Application of magnetic bearings to boiler feed pumps presents various attractive features, such as longer bearing life, lower maintenance costs, and improved operability through control of the rotordynamics. Magnetic bearings were fitted to an eight-stage, 600 hp boiler feed pump, which generates 2600 ft of heat at 680 gpm and 3560 rpm. In addition to the varied and severe operating environment in steady state operation of this pump in a power plant, it is also subjected to transient loads during frequent starts and stops. These loads can now be measured by the in-built instrumentation of the magnetic bearings. Following site installation, a follow-up bearing tune-up was performed, and pump transient response testing was conducted. The bearing response was completely satisfactory, ensuring trouble-free pump operation even in the range of reduced load. The experience gained so far through design and testing proves feasibility of magnetic bearings for boiler feed pumps, which sets the stage for application of even higher energy centrifugal pumps equipped with magnetic bearings.

Lev Nelik↗

NASA NTRS1978

Assessment of industrial applications for fuel cell cogeneration systems

The fuel cell energy systems are designed with and without a utility connection for emergency back-up power. Sale of electricity to the utility during periods of low plant demand is not considered. For each of the three industrial applications, conceptual designs were also developed for conventional utility systems relying on purchased electric power and fossil-fired boilers for steam/hot water. The capital investment for each energy system is estimated. Annual operating costs are also determined for each system. These cost estimates are converted to levelized annual costs by applying appropriate economic factors. The breakeven electricity price that would make fuel cell systems competitive with the conventional systems is plotted as a function of naphtha price. The sensitivity of the breakeven point to capital investment and coal price is also evaluated.

Stickles, R. P.↗

NASA NTRS1981

Solar Energy Systems

A waste water treatment plant in Wilton, Maine, where sludge is converted to methane gas, and Monsanto Company's Environmental Health Laboratory in St. Louis Missouri, where more than 200 solar collectors provide preheating of boiler feed water for laboratory use are representative of Grumman's Sunstream line of solar energy equipment. This equipment was developed with technology from NASA's Apollo lunar module program.

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NASA NTRS1980

Cogeneration Technology Alternatives Study (CTAS). Volume 1: Summary

Various advanced energy conversion systems that can use coal or coal-derived fuels for industrial cogeneration applications were compared to provide information needed by DOE to establish research and development funding priorities for advanced-technology systems that could significantly advance the use of coal or coal-derived fuels in industrial cogeneration. Steam turbines, diesel engines, open-cycle gas turbines, combined cycles, closed-cycle gas turbines, Stirling engines, phosphoric acid fuel cells, molten carbonate fuel cells, and thermionics were studied with technology advancements appropriate for the 1985-2000 time period. The various advanced systems were compared and evaluated for wide diversity of representative industrial plants on the basis of fuel energy savings, annual energy cost savings, emissions savings, and rate of return on investment as compared with purchasing electricity from a utility and providing process heat with an on-site boiler. Also included in the comparisons and evaluations are results extrapolated to the national level.

Barna, G. J.↗

NASA NTRS1980

Active heat exchange system development for latent heat thermal energy storage

Alternative mechanizations of active heat exchange concepts were analyzed for use with heat of fusion Phase Change Materials (PCM's) in the temperature range of 250 C to 350 C for solar and conventional power plant applications. Over 24 heat exchange concepts were reviewed, and eight were selected for detailed assessment. Two candidates were chosen for small-scale experimentation: a coated tube and shell that exchanger, and a direct contact reflux boiler. A dilute eutectic mixture of sodium nitrate and sodium hydroxide was selected as the PCM from over fifty inorganic salt mixtures investigated. Preliminary experiments with various tube coatings indicated that a nickel or chrome plating of Teflon or Ryton coating had promise of being successful. An electroless nickel plating was selected for further testing. A series of tests with nickel-plated heat transfer tubes showed that the solidifying sodium nitrate adhered to the tubes and the experiment failed to meet the required discharge heat transfer rate of 10 kW(t). Testing of the reflux boiler is under way.

Lefrois, R. T.↗

NASA NTRS1984

Cogeneration Technology Alternatives Study (CTAS). Volume 2: Comparison and evaluation of results

CTAS compared and evaluated various advanced energy conversion systems that can use coal or coal-derived fuels for industrial cogeneration applications. The principal aim of the study was to provide information needed by DOE to establish research and development (R&D) funding priorities for advanced-technology systems that could significantly advance the use of coal or coal-derived fuels in industrial cogeneration. Steam turbines, diesel engines, open-cycle gas turbines, combined cycles, closed-cycle gas turbines, Stirling engines, phosphoric acid fuel cells, molten carbonate fuel cells, and thermionics were studied with technology advancements appropriate for the 1985-2000 time period. The various advanced systems were compared and evaluated for a wide diversity of representative industrial plants on the basis of fuel energy savings, annual energy cost savings, emissions savings, and rate of return on investment (ROI) as compared with purchasing electricity from a utility and providing process heat with an on-site boiler.

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NASA NTRS1982

From Lift-Off to Light-Off

Shuttle's propellant measurement system is produced by Simmonds Precision. Company has extensive experience in fuel management systems and other equipment for military and commercial aircraft. A separate corporate entity, Industrial Controls Division was formed due to a number of non-aerospace spinoffs. One example is a "custody transfer" system for measuring and monitoring liquefied natural gas (LNG). LNG is transported aboard large tankers at minus 260 degrees Fahrenheit. Value of a single shipload may reach $15 million. Precision's LNG measurement and monitoring system aids accurate financial accounting and enhances crew safety. Custody transfer systems have been provided for 10 LNG tankers, built by Owing Shipbuilding. Simmonds also provided measurement systems for several liquefied petroleum gas (LPG) production and storage installations. Another spinoff developed by Simmonds Precision is an advanced ignition system for industrial boilers that offers savings of millions of gallons of fuel, and a computer based monitoring and control system for improving safety and reliability in electrical utility applications. Simmonds produces a line of safety systems for nuclear and non-nuclear electrical power plants.

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NASA NTRS1990

Bounding the states of systems with unknown-but-bounded disturbances

Control systems with hard constraints on certain variables are characterized, in an analytical review of recent investigations based on an unknown-but-bounded description of magnitude uncertainties. Hard-constraint problems typically arise in the design of controllers for potentially hazardous systems such as nuclear power plants. Consideration is given to norm bounds based on matrix measures, extensions of Schweppe's (1968) ellipsoid bounds, and set-theoretic regulator design. The performance of these approaches is evaluated by means of numerical simulations involving a third-order nonlinear steam-boiler model; the results are presented in graphs, and it is found that ellipsoid bounds are tightest in the general case, but that box bounds are even tighter for linear systems with Metzler system matrices.

Tsai, Wei K.↗

NASA NTRS2001

Turning Gas into Greens

Scientists from Cook College, Rutgers University, and Stevens Institute of Technology conducted studies to create an experimental greenhouse that uses methane from decomposing trash to fuel a system that makes food. Biogasses created by the anaerobically decomposing trash are necessary to fulfill the energy needs of this revolutionary greenhouse. The primary emission, methane, is piped to the greenhouse boiler and used to fuel the hot water heating system. Thus far, the use of biogas has drastically reduced the operating costs of the greenhouse, eliminating the need for non-renewable fuels. The biogas will also generate electricity for the greenhouse in the near future. The plants are irrigated with recycled plant nutrients such as nitrogen, phosphorus, potassium, calcium, and magnesium. These nutrients are delivered through hydroponics, the cultivation of plants in a nutrient solution rather than in soil. High-pressure sodium lamps augment the natural light, thereby boosting production and reducing cropping time. A total of 16 hours of light are provided to the crop each day, year-round. It only takes about 90 days for a seed to germinate and produce a tomato harvest. Not only is the food produced faster, the manual labor needed for the upkeep of the plants is also drastically reduced.

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NASA NTRS1980

Thermal energy storage and transport

The extraction of thermal energy from large LWR and coal fired plants for long distance transport to industrial and residential/commercial users is analyzed. Transport of thermal energy as high temperature water is shown to be considerably cheaper than transport as steam, hot oil, or molten salt over a wide temperature range. The delivered heat is competitive with user-generated heat from oil, coal, or electrode boilers at distances well over 50 km when the pipeline operates at high capacity factor. Results indicate that thermal energy storage makes meeting of even very low capacity factor heat demands economic and feasible and gives the utility flexibility to meet coincident electricity and heat demands effectively.

Hausz, W.↗

NASA NTRS1974

Comparative evaluation of solar, fission, fusion, and fossil energy resources. Part 4: Energy from fossil fuels

The conversion of fossil-fired power plants now burning oil or gas to burn coal is discussed along with the relaxation of air quality standards and the development of coal gasification processes to insure a continued supply of gas from coal. The location of oil fields, refining areas, natural gas fields, and pipelines in the U.S. is shown. The technologies of modern fossil-fired boilers and gas turbines are defined along with the new technologies of fluid-bed boilers and MHD generators.

Williams, J. R.↗