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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

High Performance Computing to Enable Next-Generation Low-Temperature Waste Heat Recovery

US manufacturing industry fails to recover an estimated 900 trillion BTUs of low-temperature waste heat from its processes each year. A grand research challenge has been to develop waste heat recovery technology that can be applied to industrial manufacturing processes and vehicle operations. The Oak Ridge National Laboratory (ORNL)/Eaton research team performed computational research and development to design an innovative direct-contact heat exchanger (DCHE) technology to deliver low-cost, compact, longer-lifetime, high-efficiency waste heat recovery that is optimized for a low-temperature organic Rankine cycle. ORNL resources and expertise in high performance computing (HPC) and multiphase flows were utilized to realize this goal while advancing the fundamental understanding of two-phase, two-immiscible-fluid turbulent flow heat transfer for heat exchangers. In the first stage of the project, a computational fluid dynamics (CFD) model of a DCHE was developed. Verification and limited validation of the numerical solution were performed using experimental data from published literature. To support efforts in verification and validation, two-dimensional CFD models were also developed with the objective of investigating different boundary conditions to reach converged, steady-state solutions.Based on benchmarking efforts, a baseline industry-grade design of a DCHE was developed, which consists of two horizontal pipes of different cross-sectional areas – joined by a converging-diverging nozzle in the middle and relies on a three-phase system with co-current flows for operation. Evaporation of the cold liquid (n-pentane or methanol) by the hot liquid water occurs in the first pipe. The first pipe contains two inlets for liquid water and liquid pentane (or liquid methanol). The second pipe with the larger cross-sectional area serves as a gravity-driven phase-separator. It contains two outlets that are staggered to avoid entrainment of the liquid water phase by the gas phase. This baseline design resulted from several trial-and-error evaluations using two-dimensional CFD models. Confirmatory three-dimensional CFD models were also run for different mass flow rates and inlet temperatures (inlet water temperature ranging from 50°C to 90°C), and efficiency plots were produced to fully characterize the proposed industrial-grade design of the DCHE.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2022

La–Sr–Co oxide catalysts for oxygen evolution reaction in anion exchange membrane water electrolyzer: The role of electrode fabrication on performance and durability

Anion exchange membrane water electrolysis is an attractive technology for low-cost generation of “green” hydrogen by combining the use of noble metal-free catalysts with pure water feed. By thus addressing main drawbacks of the liquid alkaline electrolysis and proton exchange membrane water electrolysis, anion exchange membrane water electrolysis stands an excellent chance of replacing the two technologies. The development of active and stable platinum group metal (PGM)-free catalysts for oxygen evolution reaction (OER) is crucial for making anion exchange membrane water electrolyzers (AEMWEs) practical. For this work, we synthesized, characterized and tested two La–Sr–Co oxide-based OER catalysts. First, we characterized the catalysts by XRD, SEM, and N 2 physisorption and assessed their OER activity in a three-electrode cell. Next, we focused on electrode fabrication, demonstrating the importance of catalyst-ink application to the porous transport layers (PTLs) and a key role of adding a binder to the catalyst ink to prevent the catalyst detachment from the PTL in pure water. We tested three membrane electrode assemblies prepared using different formulations of the anode catalyst ink. The results show that the optimum ink formulation is essential for the performance on pure-water feed by maximizing OH - conductivity of the catalyst layer and catalyst-membrane interface.

47 OTHER INSTRUMENTATION↗
NASA NTRS2016

Game Changing Development Program - Next Generation Life Support Project: Oxygen Recovery From Carbon Dioxide Using Ion Exchange Membrane Electrolysis Technology

This report summarizes the Phase I research and development work performed during the March 13, 2015 to July 13, 2016 period. The proposal for this work was submitted in response to NASA Research Announcement NNH14ZOA001N, "Space Technology Research, Development, Demonstration, and Infusion 2014 (SpaceTech-REDDI-2014)," Appendix 14GCD-C2 "Game Changing Development Program, Advanced Oxygen Recovery for Spacecraft Life Support Systems Appendix" The Task Agreement for this Phase I work is Document Control Number: GCDP-02-TA-15015. The objective of the Phase I project was to demonstrate in laboratories two Engineering Development Units (EDU) that perform critical functions of the low temperature carbon dioxide electrolysis and the catalytic conversion of carbon monoxide into carbon and carbon dioxide. The low temperature carbon dioxide electrolysis EDU was built by the University of Delaware with Dr. Feng Jiao as the principal investigator in charge of this EDU development (under NASA Contract NNC15CA04C). The carbon monoxide catalytic conversion EDU was built by the NASA Glenn Research Center with Kenneth Burke as the principal investigator and overall project leader for the development of both EDUs. Both EDUs were successfully developed and demonstrated the critical functions for each process. The carbon dioxide electrolysis EDU was delivered to the NASA Johnson Space Center and the carbon monoxide catalytic conversion EDU was delivered to the NASA Marshall Spaceflight Center.

Oxygen Recovery↗
DOE OSTI2022

Influence of Supporting Electrolyte on Hydroxide Exchange Membrane Water Electrolysis Performance: Catholyte

Alkaline or hydroxide exchange membrane water electrolysis (HEMWE) is a promising technology for green hydrogen production using platinum group metal-free catalysts and stainless steel, an advantage of alkaline water electrolysis (AWE), and a gas-impermeable membrane, a parallel to proton exchange membrane electrolysis (PEMWE). However, the HEMWE requires supporting electrolytes and there is minimal understanding of their role on the respective reactions. Without SELs, HEMWE performance and durability are worse than PEMWE systems. Herein, consistently feeding potassium hydroxide anolyte, we systematically study the effects of catholyte SELs in HEMWEs including dry vs. wet operation, cation effects, anion effects, and cation/OH ratios on cell potential and stability. We report that (i) hydration of the cathode improves high current density operation by preventing dehydration of the hydroxide exchange membrane (HEM), (ii) there was no correlation between cation type and cell potential, (iii) cell potential and high frequency resistance did not correlate with SEL conductivity, (iv) cathodic carbonate SEL had a significant negative effect on cell performance, (v) increased cation/OH ratio also caused increased cell potentials. Overall, this study concludes that feeding water or potassium hydroxide solution is desirable to improve the AEMWE performance.

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

Energy Systems Integration Partnerships: NREL + Giner

This fact sheet highlights work done at the ESIF in partnership with Giner. Giner, a developer of proton-exchange membrane (PEM) technologies, has contracted with NREL to validate the performance of its large-scale PEM electrolyzer stacks. PEM electrolyzers work much like fuel cells run in reverse.

30 DIRECT ENERGY CONVERSION↗
NASA NTRS2011

Ion Exchange Technology Development in Support of the Urine Processor Assembly Precipitation Prevention Project for the International Space Station

In support of the Urine Processor Assembly Precipitation Prevention Project (UPA PPP), multiple technologies were explored to prevent CaSO4 dot 2H2O (gypsum) precipitation during the on-orbit distillation process. Gypsum precipitation currently limits the water recovery rate onboard the International Space Station (ISS) to 70% versus the planned 85% target water recovery rate. Due to its advanced performance in removing calcium cations in pretreated augmented urine (PTAU), ion exchange was selected as one of the technologies for further development by the PPP team. A total of 12 ion exchange resins were evaluated in various equilibrium and dynamic column tests with solutions of dissolved gypsum, urine ersatz, PTAU, and PTAU brine at 85% water recovery. While initial evaluations indicated that the Purolite SST60 resin had the highest calcium capacity in PTAU (0.30 meq/mL average), later tests showed that the Dowex G26 and Amberlite FPC12H resins had the highest capacity (0.5 meq/mL average). Further dynamic column testing proved that G26 performance is +/- 10% of that value at flow rates of 0.45 and 0.79 Lph under continuous flow, and 10.45 Lph under pulsed flow. Testing at the Marshall Spaceflight Center (MSFC) integrates the ion exchange technology with a UPA ground article under flight-like pulsed flow conditions with PTAU. To date, no gypsum precipitation has taken place in any of the initial evaluations.

Mitchell, Julie L.↗
DOE OSTI2023

Ionomer-free and recyclable porous-transport electrode for high-performing proton-exchange-membrane water electrolysis

Abstract Clean hydrogen production requires large-scale deployment of water-electrolysis technologies, particularly proton-exchange-membrane water electrolyzers (PEMWEs). However, as iridium-based electrocatalysts remain the only practical option for PEMWEs, their low abundance will become a bottleneck for a sustainable hydrogen economy. Herein, we propose high-performing and durable ionomer-free porous transport electrodes (PTEs) with facile recycling features enabling Ir thrifting and reclamation. The ionomer-free porous transport electrodes offer a practical pathway to investigate the role of ionomer in the catalyst layer and, from microelectrode measurements, point to an ionomer poisoning effect for the oxygen evolution reaction. The ionomer-free porous transport electrodes demonstrate a voltage reduction of > 600 mV compared to conventional ionomer-coated porous transport electrodes at 1.8 A cm −2 and <0.1 mg Ir cm −2 , and a voltage degradation of 29 mV at average rate of 0.58 mV per 1000-cycles after 50k cycles of accelerated-stress tests at 4 A cm −2 . Moreover, the ionomer-free feature enables facile recycling of multiple components of PEMWEs, which is critical to a circular clean hydrogen economy.

08 HYDROGEN↗
DOE OSTI2016

Compact Ceramic Microchannel Heat Exchangers

The objective of the proposed work was to demonstrate the feasibility of a step change in power plant efficiency at a commercially viable cost, by obtaining performance data for prototype, compact, ceramic microchannel heat exchangers. By performing the tasks described in the initial proposal, all of the milestones were met. The work performed will advance the technology from Technology Readiness Level 3 (TRL 3) to Technology Readiness Level 4 (TRL 4) and validate the potential of using these heat exchangers for enabling high efficiency solid oxide fuel cell (SOFC) or high-temperature turbine-based power plants. The attached report will describe how this objective was met. In collaboration with The Colorado School of Mines (CSM), specifications were developed for a high temperature heat exchanger for three commercial microturbines. Microturbines were selected because they are a more mature commercial technology than SOFC, they are a low-volume and high-value target for market entry of high-temperature heat exchangers, and they are essentially scaled-down versions of turbines used in utility-scale power plants. Using these specifications, microchannel dimensions were selected to meet the performance requirements. Ceramic plates were fabricated with microchannels of these dimensions. The plates were tested at room temperature and elevated temperature. Plates were joined together to make modular, heat exchanger stacks that were tested at a variety of temperatures and flow rates. Although gas flow rates equivalent to those in microturbines could not be achieved in the laboratory environment, the results showed expected efficiencies, robust operation under significant temperature gradients at high temperature, and the ability to cycle the stacks. Details of the methods and results are presented in this final report.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Numerical Analysis of Novel Plate Type Heat Exchanger with Oval-Twisted Channels

The novel heat exchanger (HX) designs implementing geometrical and surface modification combinations are expected to perform better than traditional HX technologies. Applied enhancement techniques seek to achieve (1) higher overall heat transfer performance, (2) increased compactness, and (3) simplified or comparable manufacturability. One innovative enhancement technique is to generate swirling flow vortices induced by channel or tube twisting. The turbulence generated by the twisted cross-section greatly enhances the heat transfer rate with minimal increases in pressure drop. Plate-type HXs and Printed Circuit Heat Exchangers (PCHXs) are compact designs that achieve high heat transfer rates per unit volume by utilizing several small channels, which maximizes the heat transfer surface area between the hot and cold fluids. Currently, advanced manufacturing technologies enable the design and fabrication of compact-type units with complicated channel geometries to achieve the highest performance and meet the compactness criteria of innovative HX technology. The proposed HX design concept combines the compactness of plate-type HXs and twisted channels, which provide additional turbulence and flow swirl enhancement. The plate-type oval-twisted HX (PTOTHX) is a crossflow configuration, with 16 short channels on one side (for hot fluid) and 8 long channels on the perpendicular side (for cold fluid). The inlet plenums have flow guide vanes to redirect flow and produce uniformity across the various flow paths. The compact size and purportedly improved heat transfer performance of the PTOTHX investigated herein prove its viability in various applications. Some notable potential nuclear applications of the PTOTHX include reactor core, spent fuel cooling, and residual heat dissipation. To establish a reference case, circular channels (PTCHX) are also considered in the present study for comparison with (PTOTHX). This paper aims to outline the numerical analysis procedures for determining the viability of the PTOTHX by comparing its heat transfer performance with the PTCHX units. The computational study used STAR-CCM+, a commercial computational fluid dynamics (CFD) code. Sensitivity analysis and model selection studies are conducted to determine the appropriate mesh density and turbulence model to provide the reported results. Numerical analyses comparing the Nusselt number (Nu) of the PTOTHX design with a comparable HX unit, including a circular cross-section and no twisting (PTCHX), show an overall heat transfer performance increase of 29-55% for balanced flow and 29-59% for imbalanced flow. Oval-cross-sectional twisted channels induce swirling flow vortices, enhancing the working fluid's convective heat transfer capabilities.

25 ENERGY STORAGE↗
DOE OSTI2025

Low-cost and high-performance heat exchangers for CSP

This project aimed to design and manufacture a low-cost and high-performance, particle–to–sCO 2 heat exchanger (HX) for Concentrated Solar Power (CSP) using additive manufacturing (AM). Three enabling technologies will be integrated to achieve the targeted cost and performance. The first technology is the extreme high‐speed laser materials deposition (LMD) AM process known by its German acronym EHLA that was invented at the Fraunhofer Institute for Laser Technology. The EHLA process utilizes a specially designed powder-feeding nozzle that enables a laser to melt the powder particles above the melt pool, in contrast to the conventional LMD process where the powders are melted inside the melt pool. EHLA enables much faster deposition rate than conventional LMD without the need to wait for the powders to melt. The second technology is an innovative double-helical HX geometry that can be easily fabricated using the EHLA process by rotating a rod at a high-speed to take advantage of the high EHLA deposition rate. The double-helical fins separate the hot region (the hot particle side) and the cold region (the sCO 2 side) and provide large heat transfer surface area without a large pressure drop on the sCO 2 side. The particle side will have a larger gap to facilitate the particle flow. The outer rims of the double helixes can be sealed off using the same AM process. After sealing-off, additional double helixes can be built radially on top of the first set to improve HX performance. The HX can be installed vertically for gravity-driven flow of the hot particles if necessary. The third technology is a low-cost high-temperature alumina-forming austenitic (AFA) steel TMA-6350 that has creep and oxidation resistance up to 1100 °C. These technologies together will enable high-performance and low-cost HXs for particle–to–sCO 2 for CSP.

14 SOLAR ENERGY↗
DOE OSTI2017

Fluidized-Bed Heat Transfer Modeling for the Development of Particle/Supercritical-CO2 Heat Exchanger

Concentrating solar power (CSP) technology is moving toward high-temperature and high-performance design. One technology approach is to explore high-temperature heat-transfer fluids and storage, integrated with a high-efficiency power cycle such as the supercritical carbon dioxide (s-CO2) Brayton power cycle. The s-CO2 Brayton power system has great potential to enable the future CSP system to achieve high solar-to-electricity conversion efficiency and to reduce the cost of power generation. Solid particles have been proposed as a possible high-temperature heat-transfer medium that is inexpensive and stable at high temperatures above 1,000 degrees C. The particle/heat exchanger provides a connection between the particles and s-CO2 fluid in the emerging s-CO2 power cycles in order to meet CSP power-cycle performance targets of 50% thermal-to-electric efficiency, and dry cooling at an ambient temperature of 40 degrees C. The development goals for a particle/s-CO2 heat exchanger are to heat s-CO2 to =720 degrees C and to use direct thermal storage with low-cost, stable solid particles. This paper presents heat-transfer modeling to inform the particle/s-CO2 heat-exchanger design and assess design tradeoffs. The heat-transfer process was modeled based on a particle/s-CO2 counterflow configuration. Empirical heat-transfer correlations for the fluidized bed and s-CO2 were used in calculating the heat-transfer area and optimizing the tube layout. A 2-D computational fluid-dynamics simulation was applied for particle distribution and fluidization characterization. The operating conditions were studied from the heat-transfer analysis, and cost was estimated from the sizing of the heat exchanger. The paper shows the path in achieving the cost and performance objectives for a heat-exchanger design.

14 SOLAR ENERGY↗
NASA NTRS1985

Recent cryocooler progress in Japan

The progress of cryocoolers and related devices in Japan is reviewed. The Japanese National Railways has developed the light weight 4 K on-board refrigerators since 1977 as part of the MAGLEV train program. Superconducting and cryogenic fundamental technology was examined which included high performance cryocooler, magnetic refrigerator and superfluid refrigeration. Space cryogenics such as the cooling systems of IR-detectors was studied. Cryocooler for special applications such as cryopump, NMR-CT and JJ devices was investigated. Compact heat exchangers, high performance regenerators and reliable compressors are investigated as a critical component technology.

Matsubara, Y.↗
DOE OSTI2022

Performance Evaluation of a Prototype Moving Packed-Bed Particle/sCO 2 Heat Exchanger

Particle heat exchangers are a critical enabling technology for next generation concentrating solar power (CSP) plants that use supercritical carbon dioxide (sCO 2 ) as a working fluid. This report covers the design, manufacturing and testing of a prototype particle-to-sCO 2 heat exchanger targeting thermal performance levels required to meet commercial scale cost targets. In addition, the the design and assembly of integrated particle and sCO 2 flow loops for heat exchanger performance testing are detailed. The prototype heat exchanger was tested to particle inlet temperatures of 500 °C at 17 MPa which resulted in overall heat transfer coefficients of approximately 300 W/m 2 -K at the design point and cases using high approach temperature with peak values as high as 400 W/m 2 -K

14 SOLAR ENERGY↗
NASA NTRS2008

A Freezable Heat Exchanger for Space Suit Radiator Systems

During an ExtraVehicular Activity (EVA), both the heat generated by the astronaut s metabolism and that produced by the Portable Life Support System (PLSS) must be rejected to space. The heat sources include the heat of adsorption of metabolic CO2, the heat of condensation of water, the heat removed from the body by the liquid cooling garment and the load from the electrical components. Although the sublimator hardware to reject this load weighs only 1.58 kg (3.48 lbm), an additional 3.6 kg (8 lbm) of water are loaded into the unit, most of which is sublimated and lost to space, thus becoming the single largest expendable during an eight-hour EVA. Using a radiator to reject heat from the astronaut during an EVA can reduce the amount of expendable water consumed in the sublimator. Radiators have no moving parts and are thus highly reliable. Past freezable radiators have been too heavy, but the weight can be greatly reduced by placing a small and freeze tolerant heat exchanger between the astronaut and radiator, instead of making the very large radiator freeze tolerant. Therefore, the key technological innovation to improve space suit radiator performance was the development of a lightweight and freezable heat exchanger that accommodates the variable heat load generated by the astronaut. Herein, we present the heat transfer performance of a newly designed heat exchanger that endured several freeze / thaw cycles without any apparent damage. The heat exchanger was also able to continuously turn down or turn up the heat rejection to follow the variable load.

Nabity, James A.↗
DOE OSTI2021

Current Status on the Manufacturing of Nanomaterials for Proton Exchange Membrane Energy Systems by Vapor-Based Processes

Development of novel technologies for catalyst synthesis and membrane electrode assembly (MEA) fabrication is of primary importance for further improvement of the performance and economics of proton exchange membrane fuel cells (PEMFCs) and proton exchange membrane water electrolyzers (PEMWEs). While the traditional manufacturing methods are time-consuming, energy intensive, and require many processing steps, the new vapor-based methods provide many benefits including the development of improved catalysts and catalyst supports, deposition of uniform thin films, reduction of catalyst loading, and minimizing the number of manufacturing steps. Recent publications in the field identified spray pyrolysis, reactive spray deposition technology, chemical vapor deposition, and atomic layer deposition as advanced vapor-based catalyst synthesis and deposition methods used for fabrication of MEAs for PEMFCs and PEMWEs. Here, the MEAs fabricated via vapor-based processes have shown significant performance improvements in comparison to the state-of-the-art MEAs, which are attributed to better catalyst distribution, improved catalyst supports, and controlled, uniform catalyst layer microstructures. This review provides an overview of the vapor-based synthesis and deposition methods currently being used for the development of PEM-based devices. The advantages and disadvantages of these methods are critically compared and discussed while the outlook for future development is provided.

25 ENERGY STORAGE↗
DOE OSTI2024

Performance Evaluation of Drain Water Heat Recovery Exchangers for Heat Pump Water Heaters

Water heating constitutes approximately 18% of energy consumption and is the second largest energy expenses in United States homes. Heat pump water heaters (HPWHs) are energy efficient technologies with lower carbon footprints as compared to conventional water heating technologies, such as gas and electrical resistance heaters. The performance of water-source HPWHs can be improved by recovering heat from blackwater using drain heat recovery heat exchangers. Depending on water draw patterns of single family and multifamily residences, the operation and heat transfer performance of these heat exchangers are highly transient. This paper examines the thermo-hydraulic performance of a drain heat recovery heat exchanger during its transient and steady-state operations. The heat recovery performance of the exchanger was evaluated at different inlet temperatures and flow rates ranging from 9°C to 36°C and 0.03 kg/s to 0.28 kg/s, respectively. The obtained effectiveness varies from 45%–85% depending on the operating conditions. The test facility, steady-state and transient experimental procedures are reported in detail. Further, the effect of operating conditions on the effectiveness is discussed. The experimental approach and results of the study will provide insights into the transient operation of drain recovery heat exchangers as well as, guide sizing for various steady state conditions.

Krishnan, Easwaran↗
NASA NTRS2012

Demonstration of Passive Fuel Cell Thermal Management Technology

The NASA Glenn Research Center is developing advanced passive thermal management technology to reduce the mass and improve the reliability of space fuel cell systems for the NASA Exploration program. The passive thermal management system relies on heat conduction within highly thermally conductive cooling plates to move the heat from the central portion of the cell stack out to the edges of the fuel cell stack. Using the passive approach eliminates the need for a coolant pump and other cooling loop components within the fuel cell system which reduces mass and improves overall system reliability. Previous development demonstrated the performance of suitable highly thermally conductive cooling plates and integrated heat exchanger technology to collect the heat from the cooling plates (Ref. 1). The next step in the development of this passive thermal approach was the demonstration of the control of the heat removal process and the demonstration of the passive thermal control technology in actual fuel cell stacks. Tests were run with a simulated fuel cell stack passive thermal management system outfitted with passive cooling plates, an integrated heat exchanger and two types of cooling flow control valves. The tests were run to demonstrate the controllability of the passive thermal control approach. Finally, successful demonstrations of passive thermal control technology were conducted with fuel cell stacks from two fuel cell stack vendors.

Burke, Kenneth A.↗
DOE OSTI2025

Thrifting iridium for hydrogen

Using renewable electricity to produce hydrogen fuel reduces reliance on fossil fuels. Proton exchange membrane water electrolyzers (PEMWEs) are the highest-performing commercialized technology. These devices split water into oxygen gas and hydrogen ions (protons) at the anode. The protons then migrate through an ion-conducting polymer membrane (ionomer) to be reduced to hydrogen gas at the cathode. Further, the anode reaction’s harsh environment requires the use of precious-metal catalysts, such as iridium oxide (IrO x ). Given the expense and scarcity, the design of electrodes that minimize the use of precious metals without compromising the requisite stability and activity is desired for large-scale hydrogen production. On page 791 of this issue, Shi et al. report that anchoring IrO x catalysts onto porous cerium-oxide (CeO x ) supports maintains performance even with much reduced precious metal use.

08 HYDROGEN↗