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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 OSTI2023

Performance and Cost Potential for Direct-Fired Supercritical CO2 Natural Gas Power Plants

Direct-fired supercritical CO2 (sCO2) power cycles are being explored as an attractive alternative to natural gas combined cycle (NGCC) plants with carbon capture and storage (CCS). Therefore, understanding their performance and cost potential is important for the commercialization of the technology. This study presents the techno-economic optimization results of natural gas-fired, utility-scale power plants based on the direct sCO2 power cycle, which are lacking in public literature. To identify the optimum plant configuration, the study considered multiple cases with varying levels of thermal integration with the plant air separation unit (ASU). Several design variables for each power cycle configuration were identified and optimized to minimize the levelized cost of electricity (LCOE) for each case. The optimization design variables include the sCO2 cooler outlet temperatures, recuperator approach temperatures, and pressure drops. High fidelity models for recuperators, coolers, and turbines were developed and used to capture the impact of design variables on plant efficiency and capital costs. The optimization was conducted using a combination of manual sensitivity analyses and automated derivative-free optimization algorithms available under NETL’s Framework for Optimization and Quantification of Uncertainty and Sensitivity platform. The optimized direct sCO2 power plants offered similar or slightly higher plant efficiencies than the reference NGCC plants based on the F-class gas turbine with CCS. The LCOE of the optimized direct sCO2 plants is 13 to 17% higher than the reference NGCC plants with CCS due to high capital costs associated with the ASU and sCO2 power block, though there is significant room for improvement due to the high uncertainty in component capital costs for these new plants. Recuperators make up over 50% of the sCO2 power block costs. Consequently, any research and development efforts to reduce the recuperator capital costs will benefit the technology’s commercialization. The study also presents preliminary results showing the impact of co-firing landfill gas and natural gas on plant efficiency, LCOE, and CO2 emissions.

Pidaparti, Sandeep↗
DOE OSTI2023

Performance and Cost Potential for Direct-Fired Supercritical CO2 Natural Gas Power Plants

Direct-fired supercritical CO2 (sCO2) power cycles are being explored as an attractive alternative to natural gas combined cycle (NGCC) plants with carbon capture and storage (CCS). Therefore, understanding their performance and cost potential is important for the commercialization of the technology. This study presents the techno-economic optimization results of natural gas-fired, utility-scale power plants based on the direct sCO2 power cycle, which are lacking in public literature. To identify the optimum plant configuration, the study considered multiple cases with varying levels of thermal integration with the plant air separation unit (ASU). Several design variables for each power cycle configuration were identified and optimized to minimize the levelized cost of electricity (LCOE) for each case. The optimization design variables include the sCO2 cooler outlet temperatures, recuperator approach temperatures, and pressure drops. High fidelity models for recuperators, coolers, and turbines were developed and used to capture the impact of design variables on plant efficiency and capital costs. The optimization was conducted using a combination of manual sensitivity analyses and automated derivative-free optimization algorithms available under NETL’s Framework for Optimization and Quantification of Uncertainty and Sensitivity platform. The optimized direct sCO2 power plants offered similar or slightly higher plant efficiencies than the reference NGCC plants based on the F-class gas turbine with CCS. The LCOE of the optimized direct sCO2 plants is 13 to 17% higher than the reference NGCC plants with CCS due to high capital costs associated with the ASU and sCO2 power block, though there is significant room for improvement due to the high uncertainty in component capital costs for these new plants. Recuperators make up over 50% of the sCO2 power block costs. Consequently, any research and development efforts to reduce the recuperator capital costs will benefit the technology’s commercialization. The study also presents preliminary results showing the impact of co-firing landfill gas and natural gas on plant efficiency, LCOE, and CO2 emissions.

Pidaparti, Sandeep↗
DOE OSTI2026

Comparative assessment of new oxygen carrier materials for gas switching reforming of natural gas: Techno-economics assessment, life cycle analysis, and experimental insights

The increasing demand for hydrogen and the CO 2 intensity of natural gas (NG) reforming motivate the development of low-carbon-emission hydrogen production technologies. Gas Switching Reforming (GSR) with integrated CO 2 capture, a technology based on Chemical Looping Reforming (CLR), has been experimentally proven and shows potential for scale-up. In this study, select oxygen carriers (OC) (NiO/Al 2 O 3 , Fe 2 O 3 -CeO 2 /Al 2 O 3 , and magnetite) were tested in methane steam reforming in a fixed bed reactor to determine their relative reactivities under relevant conditions for GSR (800 °C, 7 bar total pressure). Process models were then developed to perform techno-economic analysis (TEA) of GSR for hydrogen production (GSR-H 2 ) and a combined cycle (GSR-CC) in which high-purity H 2 is fired in a gas turbine to produce electricity. Operating at 10 bar and 1100 °C and with the additional recovery steps implemented increased H 2 production by ∼ 30% and improved efficiency relative to prior studies. For GSR-H 2 , the levelized cost of hydrogen (LCOH) is 1.61–1.64 $/kg-H 2 , competitive with a reference SMR case, though operating and maintenance costs are higher due to increased electricity demand. GSR-CC has a significantly higher levelized cost of electricity (LCOE) than its reference NGCC (natural gas combined cycle) plant, suggesting it is less competitive; however, increasing production scale could make it more attractive. Life-cycle results for GSR-H 2 indicate NG consumption drives ∼ 75% of total global warming impacts (∼2.3 kg CO 2 eq/kg H 2 ). An environmental, health, and safety screening suggests iron-based carriers are comparatively safer, whereas NiO may pose greater risks. Overall, GSR-H 2 is a scalable, competitive option for hydrogen production using nickel and non-nickel OC.

03 NATURAL GAS↗
DOE OSTI2023

High Inlet Temperature Combustor for Direct-Fired Supercritical Oxy-Combustion

It is envisioned that supercritical CO 2 (sCO 2 ) electric power plant efficiencies can exceed 52% with 99% carbon capture using direct-fired oxy-combustion. Such efficiencies would be competitive with Natural Gas Combined Cycles (NGCC) and operate with nearly zero carbon emissions. To achieve high plant efficiencies, turbine inlet conditions must approach 1,200 °C at 250 bar. Such conditions, while desirable from a systems perspective, exceed the current state of the art in turbine design and materials qualification. The team of Southwest Research Institute ® (SwRI ® ), Georgia Institute of Technology (Georgia Tech), Spectral Energies, LLC (Spectral), GE Global Research (GE-GRC), and the University of Central Florida (UCF) sought to demonstrate an intermediate step toward these high efficiency plants with the development of a 1 MWth, subscale direct-fired oxy-fuel combustor. The efforts focused largely on the development of an auto-ignition based combustion system capable of providing the targeted 1200 °C and the pilot-scale plant to operate the combustor. While the project was stopped short of the commissioning and demonstration work, the advances made in this effort will reduce risks associated with chemical kinetics, thermal management, water separation, flue gas cleanup, materials selection, and corrosion in future demonstration efforts for the direct-fired oxy-fuel combustion cycles. The following report documents the design, analysis, and installation efforts completed during the project periods of performance.

03 NATURAL GAS↗
NASA NTRS1983

The coal-fired gas turbine locomotive - A new look

Advances in turbomachine technology and novel methods of coal combustion may have made possible the development of a competitive coal fired gas turbine locomotive engine. Of the combustor, thermodynamic cycle, and turbine combinations presently assessed, an external combustion closed cycle regenerative gas turbine with a fluidized bed coal combustor is judged to be the best suited for locomotive requirements. Some merit is also discerned in external combustion open cycle regenerative systems and internal combustion open cycle regenerative gas turbine systems employing a coal gasifier. The choice of an open or closed cycle depends on the selection of a working fluid and the relative advantages of loop pressurization, with air being the most attractive closed cycle working fluid on the basis of cost.

Liddle, S. G.↗
DOE OSTI2016

Chevron Natural Gas Carbon Capture Technology Testing Project (Final Technical Report)

The objective of this project was to design, construct, commission, and operate an engineering scale post combustion carbon capture system to validate the technical maturity, operability, and scalability of Svante’s VeloxoTherm™ solid sorbent carbon capture technology under representative flue gas conditions. The project was executed at Chevron’s Kern River oil field in the San Joaquin Valley of California and evaluated carbon capture performance using slipstream flue gas from natural gas fired once through steam generators (OTSG), including indicative coal and natural gas combined cycle (NGCC) operating scenarios.

03 NATURAL GAS↗
NASA NTRS1981

Comparison of Integrated Gasifier-Combined Cycle and AFB-steam turbine systems for industrial cogeneration

In the cogeneration technology alternatives study (CTAS) a number of advanced coal fired systems were examined and systems using a integrated coal gasifier IGCC or a fluid bed combustor AFB were found to yield attractive cogeneration results in industrial cogeneration applications. A range of site requirements and cogeneration sizing strategies using ground rules based on CTAS were used in comparing an IGCC and an AFB. The effect of time variations in site requirements and the sensitivity to fuel and electricity price assumptions are examined. The economic alternatives of industrial or utility ownership are also considered. The results indicate that the IGCC system has potentially higher fuel and emission savings and could be an attractive option for utility ownership. The AFB steam turbine system has a potentially higher return on investment and could be attractive assuming industrial ownership.

Nainiger, J. J.↗
NASA NTRS1981

Applications study of advanced power generation systems utilizing coal-derived fuels. Volume 1: Executive summary

The technology status of phosphoric acid and molten carbon fuel cells, combined gas and steam turbine cycles, and magnetohydrodynamic energy conversion systems was assessed and the power performance of these systems when operating with medium-Btu fuel gas whether delivered by pipeline to the power plant or in an integrated mode in which the coal gasification process and power system are closely coupled as an overall power plant was evaluated. Commercially available combined-cycle gas turbine systems can reach projected required performance levels for advanced systems using currently available technology. The phosphoric acid fuel cell appears to be the next most likely candidate for commercialization. On pipeline delivery, the systems efficiency ranges from 40.9% for the phosphoric acid fuel cell to 63% for the molten carbonate fuel cell system. The efficiencies of the integrated power plants vary from approximately 39-40% for the combined cycle to 46-47% for the molden carbonate fuel cell systems. Conventional coal-fired steam stations with flue-gas desulfurization have only 33-35% efficiency.

Robson, F. L.↗
NASA NTRS1982

A simplified design procedure for life prediction of rocket thrust chambers

An analytical procedure for predicting thrust chamber life is developed. The hot-gas-wall ligaments separating the coolant and combustion gas are subjected to pressure loading and severe thermal cycling. The resulting stresses interact during plastic straining causing incremental bulging of the ligaments during each firing cycle. This mechanism of plastic ratcheting is analyzed and a method using a yield surface for combined bending and membrane loading developed for determining the incremental permanent deflection and progressive thinning near the center of the ligaments. Fatigue and tensile instability are analyzed as possible failure modes. Results of the simplified analyses compare favorably with available experimental data and finite element analysis results for OFHC (Oxygen Free High Conductivity) copper. They are also in reasonably good agreement with experimental data for NARloy Z, a copper-zirconium-silver alloy developed by the Rocketdyne Division of Rockwell International.

Porowski, J. S.↗
NASA NTRS1977

Potential benefits of a ceramic thermal barrier coating on large power generation gas turbine

Thermal barrier coating design option offers benefit in terms of reduced electricity costs when used in utility gas turbines. Options considered include: increased firing temperature, increased component life, reduced cooling air requirements, and increased corrosion resistance (resulting in increased tolerance for dirty fuels). Performance and cost data were obtained. Simple, recuperated and combined cycle applications were considered, and distillate and residual fuels were assumed. The results indicate that thermal barrier coatings could produce large electricity cost savings if these coatings permit turbine operation with residual fuels at distillate-rated firing temperatures. The results also show that increased turbine inlet temperature can result in substantial savings in fuel and capital costs.

Clark, J. S.↗
DOE OSTI2021

Comparative Study for Pressure Gain Combustion-Gas Turbine System Performance in NGCC Configurations

The Department of Energy (DOE) has a goal to increase natural gas combined cycle (NGCC) plant efficiency to greater than 70 percent on a lower heating value (LHV) basis. Improvement in gas turbine (GT) efficiency is key achieving this goal. While many of the traditional improvement methods (higher firing temperature, advanced materials, improved cooling methods, etc.) may increase current GT and NGCC efficiencies incrementally, combining these traditional advancements with breakthrough technologies such as pressure gain combustion (PGC) may provide significant system efficiency gains. PGC is a combustion process that results in a net pressure increase across the combustor (up to pressure ratio of 2.2) rather than the traditional (<5%) pressure drop. There are multiple PGC technologies being developed that create the pressure rise phenomena, including resonant pulse combustors (RPCs), pulse detonation engines (PDEs), wave rotor combustor (WRC) engines and rotating detonation engines (RDEs). In this study, scoping analyses of PGC concepts applied to NGCC power plants were performed by combining simplified analytical models for the RPC, PDE, WRC, and RDE types of pressure gain processes with a GT model to evaluate impacts of using each of the PGC technologies on key GT performance parameters. Sensitivity analyses were also performed. Ultimately, the PGC technologies were found to have the potential to increase simple cycle efficiency by 4–6 percent (absolute) and NGCC efficiency by 2–3 percent (absolute) based on the results of the current study.

03 NATURAL GAS↗
DOE OSTI2024

Wildfire impact on soil microbiome life history traits and roles in ecosystem carbon cycling

Abstract Wildfires, which are increasing in frequency and severity with climate change, reduce soil microbial biomass and alter microbial community composition and function. The soil microbiome plays a vital role in carbon (C) and nitrogen (N) cycling, but its complexity makes it challenging to predict post-wildfire soil microbial dynamics and resulting impacts on ecosystem biogeochemistry. The application of biogeochemically relevant conceptual trait-based frameworks to the soil microbiome can distill this complexity, enabling enhanced predictability of soil microbiome recovery following wildfire and subsequent impacts to biogeochemical cycles. Conceptual frameworks that have direct links to soil C and N cycling have been developed for the soil microbiome; the Y-A-S framework overviews soil microbiome life history strategies that have tradeoffs with one another and others have proposed frameworks specific to wildfire. Here, we aimed to delineate post-wildfire changes of bacterial traits in western US coniferous forests to inform how severe wildfire influences soil microbiome recovery and resultant biogeochemical cycling. We utilized a comprehensive metagenome-assembled genome catalog from post-wildfire soils representing 1 to 11 years following low- and high-severity burning to identify traits that enable the persistence of microbial taxa in burned soils and influence ecosystem C and N cycling. We found that high-severity wildfire initially selects for fast growers and, up to a decade post-fire, taxa that invest in genes for acquiring diverse resources from the external environment, which in combination could increase soil C losses. This work begins to disentangle how climate change–induced shifts in wildfire behavior might alter microbially mediated soil biogeochemical cycling.

Nelson, Amelia R.↗
DOE OSTI2021

High Temperature CMC Nozzles for 65% Efficiency

GE Gas Power has executed a development project that targeted cooled high-temperature ceramic matrix composite (CMC) nozzles as an innovative turbomachinery component that contributes toward the DOE’s goal for advanced gas turbines that are capable of at least 65% efficiency in combined cycle application. This technology advancement has potential to also benefit gas turbines used in coal-based IGCC applications with pre-combustion carbon capture and hydrogen as the resulting fuel. The development of this technology built upon CMC capability advancements made under earlier DOE programs. The objective for this project was to develop the application of ceramic matrix composite for nozzle application in an industrial gas turbine hot gas path. The CMC component development activity done in this project facilitates high firing temperatures through improved cooling designs and concepts, better sealing, reduced leakage, advanced manufacturing processes to facilitate high performing turbomachinery, and revolutionary component architecture to improve the gas turbine performance in a combined cycle application.

20 FOSSIL-FUELED POWER PLANTS↗
NASA NTRS1978

Benefits of solar/fossil hybrid gas turbine systems

The potential benefits of solar/fossil hybrid gas turbine power systems were assessed. Both retrofit and new systems were considered from the aspects of; cost of electricity, fuel conservation, operational mode, technology requirements, and fuels flexibility. Hybrid retrofit (repowering) of existing combustion (simple Brayton cycle) turbines can provide near-term fuel savings and solar experience, while new and advanced recuperated or combined cycle systems may be an attractive fuel saving and economically competitive vehicle to transition from today's gas and oil-fired powerplants to other more abundant fuels.

Bloomfield, H. S.↗
NASA NTRS1979

Benefits of solar/fossil hybrid gas turbine systems

The potential benefits of solar/fossil hybrid gas turbine power systems were assessed. Both retrofit and new systems were considered from the aspects of cost of electricity, fuel conservation, operational mode, technology requirements, and fuels flexibility. Hybrid retrofit (repowering) of existing combustion (simple Brayton cycle) turbines can provide near-term fuel savings and solar experience, while new and advanced recuperated or combined cycle systems may be an attractive fuel saving and economically competitive vehicle to transition from today's gas and oil-fired powerplants to other more abundant fuels.

Bloomfield, H. S.↗
DOE OSTI2024

Effects of fire and fire-induced changes in soil properties on post-burn soil respiration

Boreal forests cover vast areas of land in the northern hemisphere and store large amounts of carbon (C) both aboveground and belowground. Wildfires, which are a primary ecosystem disturbance of boreal forests, affect soil C via combustion and transformation of organic matter during the fire itself and via changes in plant growth and microbial activity post-fire. Wildfire regimes in many areas of the boreal forests of North America are shifting towards more frequent and severe fires driven by changing climate. As wildfire regimes shift and the effects of fire on belowground microbial community composition are becoming clearer, there is a need to link fire-induced changes in soil properties to changes in microbial functions, such as respiration, in order to better predict the impact of future fires on C cycling. We used laboratory burns to simulate boreal crown fires on both organic-rich and sandy soil cores collected from Wood Buffalo National Park, Alberta, Canada, to measure the effects of burning on soil properties including pH, total C, and total nitrogen (N). We used 70-day soil incubations and two-pool exponential decay models to characterize the impacts of burning and its resulting changes in soil properties on soil respiration. Laboratory burns successfully captured a range of soil temperatures that were realistic for natural wildfire events. We found that burning increased pH and caused small decreases in C:N in organic soil. Overall, respiration per gram total (post-burn) C in burned soil cores was 16% lower than in corresponding unburned control cores, indicating that soil C lost during a burn may be partially offset by burn-induced decreases in respiration rates. Simultaneously, burning altered how remaining C cycled, causing an increase in the proportion of C represented in the modeled slow-cycling vs. fast-cycling C pool as well as an increase in fast-cycling C decomposition rates. Together, our findings imply that C storage in boreal forests following wildfires will be driven by the combination of C losses during the fire itself as well as fire-induced changes to the soil C pool that modulate post-fire respiration rates. Moving forward, we will pair these results with soil microbial community data to understand how fire-induced changes in microbial community composition may influence respiration.

54 ENVIRONMENTAL SCIENCES↗
NASA NTRS1990

Design, Evaluation and Experimental Effort Toward Development of a High Strain Composite Wing for Navy Aircraft

This design development effort addressed significant technical issues concerning the use and benefits of high strain composite wing structures (Epsilon(sub ult) = 6000 micro-in/in) for future Navy aircraft. These issues were concerned primarily with the structural integrity and durability of the innovative design concepts and manufacturing techniques which permitted a 50 percent increase in design ultimate strain level (while maintaining the same fiber/resin system) as well as damage tolerance and survivability requirements. An extensive test effort consisting of a progressive series of coupon and major element tests was an integral part of this development effort, and culminated in the design, fabrication and test of a major full-scale wing box component. The successful completion of the tests demonstrated the structural integrity, durability and benefits of the design. Low energy impact testing followed by fatigue cycling verified the damage tolerance concepts incorporated within the structure. Finally, live fire ballistic testing confirmed the survivability of the design. The potential benefits of combining newer/emerging composite materials and new or previously developed high strain wing design to maximize structural efficiency and reduce fabrication costs was the subject of subsequent preliminary design and experimental evaluation effort.

Bruno, Joseph↗
NASA NTRSDate not supplied

Advancement of Extreme Environment Additively Manufactured Alloys for Next Generation Space Propulsion Applications

The National Aeronautics and Space Administration (NASA) has been involved in the development and maturation of metal additive manufacturing (AM) for space applications since the late 2000’s. Several efforts focused on the understanding of AM processes through material characterization and testing, standards development, component fabrication, and infusion into propulsion development and flight applications. NASA matured commonly used aerospace alloys from various alloy families (Nickel, Copper, Stainless and Steel, Aluminum, and Titanium-based) through detailed AM process and heat treatment characterization, in addition to mechanical and thermophysical testing. While these alloys are actively used in many propulsion applications, there is a need for ongoing AM optimized alloys using integrated computational materials engineering (ICME) and process development for high performance applications. The applications targeted are liquid rocket engines; advanced propulsion systems; and in-space propulsion with high heat fluxes, high pressure, and/or that use propellants that can degrade alloys (e.g., hydrogen). This paper highlights the characterization and physical properties of the more common AM alloys using laser powder bed fusion (L-PBF) and laser powder directed energy deposition (LP-DED) processes. Additionally, this paper discusses some of the ongoing novel alloy development and maturation using AM for use in these harsh environments, such as GRCop42, GRCop-84, NASA HR-1, GRX-810, and C-103. The results from these processes demonstrated that AM could enable rapid development and ongoing efforts for optimized alloys using ICME, yielding higher performances. These alloys have undergone modeling, fundamental metallurgical evaluations, heat treatment studies, detailed microstructure characterization, and mechanical testing campaigns. This, combined with direct application-specific component fabrication and hot-fire testing, enabled the increase of the Technology Readiness Level (TRL) through high duty-cycle testing. A background and overview of these novel AM-enabled alloys and AM processing developments including metallurgical and mechanical property studies is presented here. The latest advancement in the parallel component development and hot-fire testing and future developments for these alloys is also discussed.

Additive Manufacturing↗