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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

A New Understanding of Decarbonizing Industrial Process Heat

Analysis conducted over the last few years has improved our understanding of how industrial process heat is used in the United States. These improvements are important for characterizing the possibilities for industrial decarbonization. However, this analysis has largely been conducted from technical perspective and has remained disconnected from the social processes that underlie how industrial firms may adopt and implement technologies to decarbonize their process heating operations. This presentation introduces the concept of generic and configurational technology systems, and outlines the how the incorporation of user requirements and local contexts are essential for successful implementation of configurational systems. Insights drawn from semi-structured interviews with representatives of industrial firms are used to support the hypothesis that industrial process heat technologies are configurational. The potential implications for strategies to decarbonize process heat are then discussed.

adoption↗
DOE OSTI2014

Synthesis and characterization of nanocrystalline graphite from coconut shell with heating process

Graphite were synthesized and characterized by heating process of coconut shell with varying temperature (400, 800 and 1000°C) and holding time (3 and 5 hours). After heating process, the samples were characterized by X-ray diffraction (XRD) and analyzed by X'pert HighScore Plus Software, Scanning Electron Microcope-Energy Dispersive X-Ray (SEM-EDX) and Transmission Electron Microscope-Energy Dispersive X-Ray (TEM-EDX). Graphite and londsdaelite phase were analyzed by XRD. According to EDX analysis, the sample was heated in 1000°C got the highest content of carbon. The amorphous carbon and nanocrystalline graphite were observed by SEM-EDX and TEM-EDX.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2017

SAM Process Heat Model Development and Validation: Liquid-HTF Trough and Direct Steam Generation Linear Focus Systems

Two new solar industrial process heat (SIPH) models have been added to the System Advisor Model (SAM) energy simulation tool. The two process heat models were: i) liquid-heat transfer fluid (HTF) parabolic troughs; and ii) direct steam generation (DSG) linear-focus collectors. The DSG model can simulate either DSG parabolic troughs (PT) or DSG Linear Fresnel (LF) fields, based on the optical characteristics supplied. These models help to meet the need for independent, validated tools that reliably simulate the effects of adding a solar field to provide heat for potential IPH applications. During the pre-validation of the liquid-HTF model, operational data was provided and preprocessed by SPF and evaluated at ZAE Bayern. The beta liquid-HTF model provided excellent agreement between the simulations and the operational data for the solar thermal yield generation on a yearly and monthly basis (4.4% difference). The final liquid-HTF process heat model has been further optimized with test users such as ZAE Bayern and SPF. Key improvements in the SIPH models to better model SIPH fields include the use of smaller piping systems and heat capacities, a single collector field, and a higher time-step resolution than for electricity generation (down to 10 minutes). Both the final liquid-HTF and DSG models were successfully validated against operational data for respective solar fields, and showed less than 5% deviation to actual results. A brief application where the liquid-HTF process heat model is used for a brewery in California and the value of reliably simulating a potential SIPH solar field are highlighted.

14 SOLAR ENERGY↗
DOE OSTI2021

Opportunities for Solar Industrial Process Heat in the United States

Energy used in the production and processing of materials and products represents a significant fraction of the overall energy footprint of the industrial sector. Solar technologies may provide suitable alternative to existing combustion technologies, but their relevance for industries in the United States has been largely unexplored at the necessary levels of spatial, temporal, and operational detail. To provide the first assessment of the technical opportunities for solar technologies to meet the demand for process heat in the United States, we first develop estimates of energy use by process temperature at the county and hourly resolutions for all manufacturing industries. We then estimate the opportunities for seven solar technology packages—comprised of solar thermal and photovoltaic-connected electrotechnologies—to meet process heat demand given solar resources and available land area by county.

14 SOLAR ENERGY↗
DOE OSTI2013

Flexible Opportunity Fuels for Process Heat and Steam Generation

The majority of industrial process heating and steam generation is currently fueled by natural gas or coal. Other fuels that are not used throughout industry, such as biomass, anaerobic digester gas and petroleum coke can potentially supplement or replace natural gas and coal in various process heating and steam generation applications. These non-traditional fuel supply options, also known as opportunity fuels, can enhance energy security for industrial facilities by increasing fuel flexibility and reducing or eliminating reliance on traditional fossil fuels. They can also provide significant economic benefits, by reducing fuel costs and improving profit margins. Some fuels may even be available at a negative cost, as owners seek to dispose of waste products that may have energy content.

Lemar, Jr, Paul L.↗
DOE OSTI2021

The impact of r -process heating on the dynamics of neutron star merger accretion disc winds and their electromagnetic radiation

Neutron star merger accretion discs can launch neutron-rich winds of >10 -2 M⊙. This ejecta is a prime site for r-process nucleosynthesis, which will produce a range of radioactive heavy nuclei. The decay of these nuclei releases enough energy to accelerate portions of the wind by ~0.1c. Here, we investigate the effect of r-process heating on the dynamical evolution of disc winds. We extract the wind from a 3D general relativistic magnetohydrodynamic simulation of a disc from a post-merger system. This is used to create inner boundary conditions for 2D hydrodynamic simulations that continue the original 3D simulation. We perform two such simulations: one that includes the r-process heating, and another one that does not. We follow the hydrodynamic simulations until the winds reach homology (60 s). Using time-dependent multifrequency multidimensional Monte Carlo radiation transport simulations, we then calculate the kilonova light curves from the winds with and without dynamical r-process heating. We find that the r-process heating can substantially alter the velocity distribution of the wind, shifting the mass-weighted median velocity from 0.06c to 0.12c. The inclusion of the dynamical r-process heating makes the light curve brighter and bluer at $\sim 1\, \mathrm{d}$ post-merger. However, the high-velocity tail of the ejecta distribution and the early ($\lesssim 1\, \mathrm{d}$) light curves are largely unaffected.

79 ASTRONOMY AND ASTROPHYSICS↗
NASA NTRS1992

Coronal loops - Current-based heating processes

Based on new observations, a theoretical model of magnetic-field related heating processes in the solar corona is given. In this model, field-aligned currents are induced along coronal loops in thin current sheaths. Excitation of instabilities involving magnetic reconnection converts the energy associated with the current-related magnetic field directly into particle energy, where the heating process proceeds via short bursts corresponding to an intermittent disruption of the current sheath configuration. Because of the relatively low transverse thermal conduction, only a small fraction of the loop volume is heated to a much higher temperature than the average value. This is consistent with experimental observations of low filling factors of hot plasmas in coronal loops. Thus the model involves a repeated sequence of dynamic events taking into account the observed loop topology, the differential emission measure distribution in the 10 exp 6 - 10 exp 7 K range, the energy balance requirements in the loop, and the probable duty cycles involved in the heating processes.

Beaufume, P.↗
DOE OSTI2022

Simulating a solar parabolic trough collector plant used for industrial process heat using an optimized operating scheme that utilizes flexible heat integration

This study focuses on the modeling and simulation of a novel design and operation of a solar industrial process heat (SIPH) plant that uses a parabolic trough collector system for generating process heat. The SIPH plant incorporates flexible heat integration (FHI) by having two options for heat sinks as well as a flexible collection temperature for the heat transfer fluid. Leveraging the degrees of freedom created by FHI allows an optimized operating scheme to be created which maximizes the solar heat delivered to the industrial processes. Yearly results for a 27 MW-t plant located in Salt Lake City, UT are simulated for a base case and a case utilizing optimized FHI. For the main process temperature case presented, FHI increases the total solar share by 13.0% and reduces the levelized cost of heat of the SIPH plant by 10.4% relative to the base case. Furthermore, three case study days are presented which highlight how FHI maximizes solar share, specifically during mornings, afternoons, and days with intermittent solar conditions. An environmental analysis is also performed showing that the SIPH plant can reduce harmful emissions by 15.4% for the base case and 17.4% for the FHI case compared to a plant that only utilizes a natural gas furnace for process heat. Overall, the work thoroughly explores an effective operating scheme for a SIPH plant, helping to make it more economical and environmentally beneficial.

14 SOLAR ENERGY↗
DOE OSTI2016

Improving Process Heating System Performance v3

Improving Process Heating System Performance: A Sourcebook for Industry is a development of the U.S. Department of Energy (DOE) Advanced Manufacturing Office (AMO) and the Industrial Heating Equipment Association (IHEA). The AMO and IHEA undertook this project as part of an series of sourcebook publications developed by AMO on energy-consuming industrial systems, and opportunities to improve performance. Other topics in this series include compressed air systems, pumping systems, fan systems, steam systems, and motors and drives

U.S. DOE, IHEA, Lawrence Berkeley National Laborat↗
DOE OSTI2024

Parabolic Trough Collector Cost Update for Industrial Process Heat In The United States

Despite great potential, the worldwide adoption of concentrating solar thermal (CST) collectors for solar industrial process heat (SIPH) is modest. Industrial process heat (IPH) demands for heat and steam are typically below 300 degrees C, where CST collectors can provide the needed heat. Parabolic trough collectors (PTCs) are the most deployed CST technology for SIPH applications. This paper is focused on the United States, and a summary of known operating parabolic trough plants is shown. A previous analysis of a modern PTC in 2016 found that for SIPH applications, the installed solar field cost could be $200/m2 (2016$). Recent advances in PTC design and manufacturing have led to reduced cost per square meter of aperture area, and for a field of 510 solar collector assemblies (SCAs), the installed cost was $120/m2 (2020$). On one hand, the results from this study showed that the solar field cost for large solar fields (510 SCAs or ~804,000 m2) would increase to $184/m2 (2023$) due to post pandemic inflation and increase in metal prices. On the other hand, medium SIPH sized fields (90 SCAs or ~142,000 m2) cost analysis indicated an installed cost could be $197/m2 (2023$). When small SIPH fields (12 SCAs or ~19,000 m2) are considered, this jumps to $297/m2 (2023$). These are cost estimates for the Installed Cost of the solar fields using the United States 2023$ steel prices. When Chinese steel is used for comparison, the installed cost could be between $162 - $210/m2 for the range of SIPH sizes.

concentrating solar thermal↗
NASA NTRS1978

Agricultural and industrial process heat

The application of solar energy to agricultural and industrial process heat requirements is discussed. This energy end use sector has been the largest and it appears that solar energy can, when fully developed and commercialized, displace from three to eight or more quads of oil and natural gas in U.S. industry. This potential for fossil fuel displacement in the agricultural and industrial process heat area sector represents a possible savings of 1.4 to 3.8 million barrels of oil daily.

Dollard, J.↗
NASA NTRS1979

Solar energy for industrial process heat

Findings of study of potential use for solar energy utilization by California dairy industry, prove that applicable solar energy system furnish much of heat needed for milk processing with large savings in expenditures for oil and gas and ensurance of adequate readily available sources of process heat.

Barbieri, R. H.↗
DOE OSTI2024

Competitiveness Assessment of Decarbonizing Electricity and Process Heat Supply to a Campus with a Small Nuclear Reactor

This paper analyzes the competitiveness of siting a small nuclear reactor to support decarbonization of sites requiring tens of MW of electricity and/or process heat to support centralized heating and cooling system. This paper focuses on campuses as representative of sites with collections of buildings and research facilities with decarbonization needs represented by buildings heating, and electricity consumption by electrical loads which may include cooling via chilled water (e.g., for air conditioning and to cool down computer clusters). A nuclear reactor can be considered to decarbonize a site’s high-temperature steam generation used mostly for building heating needs, climate control, and hot water, by supplying process heat capabilities, while electricity decarbonization would be achieved mostly by the grid. However, a secondary application can be considered to maximize reactor utilization and avoid ramping down the reactor if the steam demand varies significantly throughout the year. Chilled water generation through steam-driven systems was identified as an attractive secondary option for the site analyzed, due to potential for plant design simplification, while electricity generation could be considered as well to reduce electricity purchases for a wider range of site applications. For a campus with peak 60MW thermal power demand, a small nuclear reactor with similar thermal power rating would almost eliminate CO2 emissions from steam generation and reduce electricity imports for chilled water production. A preliminary techno-economic feasibility study shows that a small nuclear reactor design that is optimized to support process heat can represent an economically feasible option when compared with other decarbonization alternatives.

Stauff, Nicolas E.↗
DOE OSTI2026

Solar Thermal Energy Planner (STEP 1): A New Decision Support Tool for Solar Industrial Process Heat Applications

Solar thermal technologies are a promising technology to supply low-cost thermal energy to industrial processes, but there are often significant barriers to entry to industrial owners considering these technologies for their energy demands. To overcome this barrier and convey economic value to customers, NREL and Sandia National Laboratories developed Solar Thermal Energy Planner (STEP 1), a new web-based decision support tool for solar industrial process heat systems. At SolarPACES 2024, the STEP 1 tool was still under development; progress, methodologies, and a preliminary case study was presented. With the STEP 1 tool launch in May 2025, in this work, the initial version of the full public tool will be presented with demonstrations of its capabilities using a few case studies. First, the user's process heat needs such as location, process media (e.g., steam, air), process temperature, land availability, electricity and fuel costs, among other parameters. STEP 1 features a mapping interface that allows users to draw land and roof boundaries. The process media and temperature inform technology selection criteria modules that determine the appropriate solar thermal collection technologies, as well as congruent heat transfer media (e.g., hot water, oil, salt). Once the solar thermal technology selected, its nominal thermal production for the given site is characterized using NREL's System Advisor Model (SAM). Then, a modified version of NREL's REopt optimal sizing and dispatch optimization tool determines cost-optimal sizing. Within minutes, the user receives the results of the technoeconomics analysis, including the size and performance of the cost-optimal solar-plus-storage system. The cost of the system is compared to business-as-usual (e.g., an existing, standalone natural gas boiler). Users can download key results to store for sensitivity analyses. Examples of flat plate collector, parabolic trough, and molten salt tower applications with and without PV hybridization for different industrial facility types are presented in this work. The STEP 1 tool aims to reduce barriers to the adoption of solar heating solutions stemming from a lack of familiarity and technical background with solar system design options and costs among industry stakeholders.

14 SOLAR ENERGY↗
DOE OSTI2016

Potential for Solar Industrial Process Heat in the United States: A Look at California

The use of Concentrating Solar Power (CSP) collectors (e.g., parabolic trough or linear Fresnel systems) for industrial thermal applications has been increasing in global interest in the last few years. In particular, the European Union has been tracking the deployment of Solar Industrial Process Heat (SIPH) plants. Although relatively few plants have been deployed in the United States (U.S.), we establish that 29% of primary energy consumption in the U.S. manufacturing sector is used for process heating. Perhaps the best opportunities for SIPH reside in the state of California due to its excellent solar resource, strong industrial base, and solar-friendly policies. This initial analysis identified 48 TWhth/year of process heat demand in certain California industries versus a technical solar-thermal energy potential of 23,000 TWhth/year. The top five users of industrial steam in the state are highlighted and special attention paid to the food sector that has been an early adopter of SIPH in other countries. A comparison of the cost of heat from solar-thermal collectors versus the cost of industrial natural gas in California indicates that SIPH may be cost effective even under the relatively low gas prices seen in 2014. A recommended next step is the identification of pilot project candidates to promote the deployment of SIPH facilities.

14 SOLAR ENERGY↗
DOE OSTI2022

Chapter 10: Process Heating for Industry

The overall objective of this chapter is to help the reader better understand the technical feasibility, barriers and opportunities for renewable thermal energy systems (RTES). Solar thermal (ST) derived heat, which can be concentrating or non-concentrating, can be considered a sub-set of RTES solutions that can provide heat for industry. This chapter will focus on Industrial Process Heat (IPH) and District Heating Systems and will also highlight the difference between stand-alone and hybrid solutions. Different thermal energy sources (traditional and new) and technologies, that can provide the end-user heat delivered through many mediums, systems and for different purposes. Among various RTES, ST technologies will be the focus of this chapter.

district heating↗
DOE OSTI2016

Solar Process Heat Potential in California, USA

The cost for solar industrial process heat (SIPH) is quantified by defining the levelized cost of heat (LCOH). The state of California, in the United States offers a favorable environment for SIPH given its excellent insolation, industrial gas prices typically higher than the national average, and policies promoting solarthermal deployment. Given historically low gas prices, competing with natural gas remains the primary challenge to deployment. However, this study finds that the solar LCOH from Concentrating Solar Power (CSP) collectors for many regions in California is expected to be lower than the LCOH from natural gas, using a representative installed solar hardware price and the average price for industrial natural gas in California. Lastly, modifications are in progress to the parabolic trough and Direct Steam Generation (DSG) trough and Linear Fresnel models within NREL's System Advisor Model (SAM) to allow users to more easily predict performance for these industrial heat and steam-generation applications.

14 SOLAR ENERGY↗