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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 361 records · Page 20
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Techno-economic analysis and environmental benefits of solar industrial process heating based on parabolic trough collectors

In this work, detailed techno-economic and environmental analyses are conducted for employing a 5 MWt parabolic trough-based solar industrial process heat (SIPH) plant in Salt Lake City, Utah. According to the results, an optimum solar multiple of 1.5 was determined, allowing the plant to generate annual thermal energy of 15389.24 MWth with a capacity factor of 35.1% and levelized cost of heat (LCOH) of $\$ 26.3$/MWth. Considering a 30% investment tax credit and a 30% reduction in the total installed cost could reduce the LCOH to $\$ 19.30$/MWth and $\$ 18.52$/MWth, respectively. Employing parabolic trough collectors could avoid emissions of 3,582,422.47 kg, 147.99 kg, 3,341.66 kg, and 14.32 kg for CO 2 , PM, NOx, and SO 2 , respectively per year compared to a natural gas-based plant. Further, it also caused an annual external cost savings of between $\$ 99,900$ and $\$ 357,004$. Including the external costs in the LCOH analysis shows that the SIPH plant is economically competitive with a natural gas-based plant, further demonstrating its value. A further comparison demonstrated the economic superiority of a parabolic trough-driven IPH plant over a photovoltaic-driven electric boiler plant. In summary, with reducing installed costs and providing incentives, parabolic trough-driven IPH plants will be an economically and environmentally viable option.

14 SOLAR ENERGY↗
DOE OSTI2022

Large scale energy analysis and renovation strategies for social housing in the historic city of Venice

Social houses built after the Second World War to accommodate workers and low-income families represent one of the major energy consumers and greenhouse gas emitters in the residential sector. Plans for their renovation are underway in all European countries, and the process is more complicated for Italian cities due to the lack of space and the large number of historical buildings. This study addresses this challenge by proposing a methodology to renovate a low-income district in the city of Venice using CityBES to model and evaluate energy conservation measures. CityBES is a web-based tool that allows users to employ urban building energy modeling for large-scale energy and retrofit analyses of building stocks. In the case study conducted for Venice's Santa Marta district, due to the particular context, four common energy conservation measures covering both the building envelope and heat generation boilers have been applied. The evaluation of energy-saving performances at the district level showed that the four measures together achieved 67% energy savings, an abatement in energy cost equal to 67%, and annual carbon dioxide emissions reduction of 1.1 MtCO 2 . Furthermore, the case study demonstrates a method and workflow replicable for energy retrofit analysis of building stocks in other historical districts.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Structural design challenges and implications for high temperature concentrating solar power receivers

High operating temperatures along with diurnal cycling and high operating stresses bring many material and engineering challenges for concentrated solar power (CSP) receivers. Current design rules in ASME Boiler and Pressure Vessel (B&PV) Code for high temperature structural components were not intended for CSP components. The paper reviews the design rules in several sections of ASME B&PV Code in terms of their applicability in designing high temperature CSP receivers. With some restrictions and modifications, the conditions assumed in the design rules in Section III, Division 5 of ASME B&PV Code are found to closely resemble the loading conditions of CSP receiver, including accounting for the interaction between creep and fatigue damage. Further, the paper applies the proposed design rules to an external tubular receiver design and discusses several lessons learned from the design study. The creep damage accumulation due to high thermal stresses resulting from circumferentially non-uniform flux distribution is found to control the design of CSP receivers. Several mitigation actions to improve the design life of receivers are also discussed.

14 SOLAR ENERGY↗
DOE OSTI2025

Techno-economic design of a linear Fresnel reflector for industrial process heat

A techno-economic model of a Concentrating Solar Thermal (CST) system using a Linear Fresnel Reflector (LFR) has been developed. LFRs can deliver process heat suitable for a range of industries, including food and beverage production. This model uses an adaptive algorithm to calculate the optimal secondary reflector shape given the geometry and optical properties of the rest of the system. A ray-tracing program is used to calculate optical efficiency over a wide range of longitudinal and transversal incidence angles and subsequently evaluate the annual efficiency at a given geographical location. A specific LFR design developed by Hyperlight Energy was modelled, and this industrial partner provided a detailed cost breakdown which was used as the basis of an economic model. Combining the technical and economic data facilitates the calculation of the Levelized Cost of Heat (LCOH). The influence of a number of parameters on the annual efficiency and LCOH is explored; notable parameters include the absorber height, the number, width, and spacing of the primary mirrors, the aim point, and the secondary reflector shape and width. By identifying an optimal combination of these parameters, we reduce the LCOH of the industry partner’s system design by 9.2%, from 14.4 $\$/MWh_{th}$ to 13.0 $\$/MWh_{th}$. In comparison, the LCOH of a natural gas boiler delivering the same annual quantity of heat is 29 $\$/MWh_{th}$, which indicates that LFRs can be a competitive heat source for industrial processes.

14 SOLAR ENERGY↗
DOE OSTI2022

Life cycle assessment of utilizing freshly cut urban wood: A case study

Large amounts of urban wood resources are generated through tree removals in urban areas. Therefore, there is a growing interest to improve the environmental performance of the urban wood supply chain by quantifying the environmental impacts of creating high-value products from urban tree removals to enhance its utilization. By surveying existing urban wood utilization operations for primary data in two major cities: Baltimore, Maryland, and Milwaukee, Wisconsin, a new life cycle inventory (LCI) dataset per m 3 of dry urban hardwood lumber and live edge slabs was created. Incorporating the new LCI data into life cycle assessment method, the total global warming (GW) impact of converting urban trees to kiln-dried lumber was estimated to be 122 kg CO 2 eq and 336 kg CO 2 eq per m 3 of lumber produced for Baltimore and Milwaukee, respectively. In both cases, the total environmental impact of the product was dominated by the conversion of urban trees to kiln dried lumber at the sawmill processing stage. Using scenario analysis for the source of heat generation used in kiln (force) drying wood, substituting wood fuel from coproducts for natural gas in a boiler for Milwaukee resulted in a substantial reduction in fossil-derived GW impact. Urban and traditional hardwood lumber production follow similar GW impact trajectories over their life-cycle stages with the lumber processing stage having the highest environmental impacts for both. Finally, increasing the overall lumber yield and decreasing kiln (force) drying would substantially improve the environmental performance of urban hardwood lumber and help make it comparable to traditional lumber.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Machine learning for ultrasonic nondestructive examination of welding defects: A systematic review

Recent years have seen a substantial increase in the application of machine learning (ML) for automated analysis of nondestructive examination (NDE) data. One of the applications of interest is the use of ML for the analysis of data from in-service inspection of welds in nuclear power and other industries. These types of inspections are performed in accordance with criteria described in the ASME Boiler and Pressure Vessel Code and require the use of reliable NDE techniques. The rapid growth in ML methods and the diversity of possible approaches indicate a need to assess the current capabilities of ML and automated data analysis for NDE and identify any gaps or shortcomings in current ML technologies as applied to the automated analysis of NDE data. In particular, there is a need to determine the impact of ML on the NDE reliability. This paper discusses the findings from a literature survey on the current state of ML for the automated analysis of data from ultrasonic NDE of weld flaws. It discusses an overview of ultrasonic NDE as used for weld inspections in nuclear power and other industries. Herein, data sets and ML models used in the literature are summarized, along with a generally applicable workflow for ML. Findings on the capabilities, limitations and potential gaps in feature selection, data selection, and ML model optimization are discussed. The paper identified several needs for quantifying and validating the performance of ML methods for ultrasonic NDE, including the need for common data sets.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Co-design optimization of combined heat and power-based microgrids

With the emergent need for clean and reliable energy resources, hybrid energy systems, such as the microgrid, are widely adopted in the United States. A microgrid can consist of various distributed energy resources, for instance, combined heat and power (CHP) systems. Here, the CHP module is a distributed cogeneration technology that produces electricity and recaptures heat generated as a by-product. It is an energy-efficient technology converting heat that would otherwise be wasted to valuable thermal energy. For an optimal system configuration, this study develops a novel co-design optimization framework for CHP-based cogeneration microgrids. The framework provides the stakeholder with a method to optimize investments and attain resilient operations. The proposed co-design framework has a mixed integer programming (MIP) model that outputs decisions for both plant designs and operating controls. The microgrid considered in this study contains six components: the CHP, boiler, heat recovery unit, thermal storage system, power storage system, and photovoltaic plant. After solving the MIP model, the optimal design parameters of each component can be found to minimize the total installation cost of all components in the microgrid. Furthermore, the online costs from energy production, operation, maintenance, machine startup, and disruption-induced unsatisfied loads are minimized by solving the optimal control decisions for operations. Case studies based on designing a CHP-based microgrid with empirical data are conducted. Moreover, we consider both nominal and disruptive operational scenarios to validate the performance of the proposed co-design framework in terms of a cost-effective, resilient system.

42 ENGINEERING↗
DOE OSTI2022

A Structural Design Approach Tailored for the Rapid Preliminary Design of Microreactor Components

High-temperature microreactors can play a role in developing reliable, portable energy sources for off-grid remote locations, microgrid concepts, and industrial process heat. Portability and passive safety criteria tend to skew microreactor structural component designs toward complex geometries, high thermal stresses, and design bases with large numbers of startup/shutdown cycles. Current design rules, as typified by Section III of the American Society of Mechanical Engineers (ASME) Boiler & Pressure Vessel Code, are less than optimal for these conditions, particularly for preliminary component designs where developers need to rapidly consider a large number of potential component configurations. This paper presents a design method targeted toward rapid, efficient evaluation of preliminary component designs using modern finite element analysis. The new method retains key connections with the ASME Code rules and design data while streamlining the design approach. This paper presents the design method, several verification examples illustrating the similarities and differences between the new method and the current ASME rules, and the application of the new approach to the evaluation of a test article mimicking key features of a heat pipe–cooled microreactor.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

A Review of Remote Welding and Nondestructive Examination Technologies for the DOE Standard Canister

The U.S. Department of Energy (DOE) manages a wide variety of spent nuclear fuel (SNF) that poses a unique management challenge. To help address this challenge, the DOE Standard Canister (DOESC), designed to remain sealed during handling, storage, transportation, and disposal, was conceptualized as a standardized containment vessel to accommodate DOE-managed SNF. Since 1999, several welding and examination processes have been independently developed for the DOESC’s closure welds. However, neither the DOESC nor these processes have been realized in an operational capacity. This review paper seeks to present and compare previously developed DOESC closure weld, nondestructive examination, and repair processes and technologies. Specific processes developed for the Idaho Spent Fuel Facility, in preparation for the Yucca Mountain geological repository, and the recent Road-Ready Demonstration Project are discussed. Further, specific focus is given to how different operating constraints and the American Society of Mechanical Engineers Boiler and Pressure Vessel Code (BPVC) have driven certain welding and nondestructive examination requirements. Historical DOESC welding and examination strategies are assessed against current regulatory and BPVC requirements. The comparison of welding processes, technologies, and DOESC designs presented in this review paper will inform further construction efforts for other commercial and DOE-managed SNF containments, including the DOESC.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Structural Design and Modeling of MARVEL Primary Coolant System Using the ASME Section III, Division 5, Code

This paper presents the structural design and supporting analysis for the Microreactor Applications Research Validation and Evaluation (MARVEL) primary coolant system (PCS) using the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code Section III, Division 5, rules. MARVEL is a liquid metal–cooled microreactor intended to provide experimental capabilities for the rapid testing and development of microreactor technologies. The PCS utilizes high-temperature sodium-potassium liquid metal as the primary coolant and operates at a design temperature of 570°C, necessitating the consideration of creep-related failure mechanisms. The base metal for the PCS is 316H stainless steel, and the weldments are made with a 16-8-2 filler. The design approach incorporates the current base code rules along with ASME code cases N-924, N-861, and N-862 to address primary load, ratcheting, and creep-fatigue evaluations, respectively. The reactor’s operation involves complex thermal and mechanical interactions due to natural convective flow and differential thermal expansion between components. In conclusion, this paper discusses the structural engineering challenges encountered, such as managing thermal stresses in the distribution plenum and guard vessel, and outlines the strategies implemented to meet the code requirements, including design modifications and operational constraints.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗
DOE OSTI2025

Design Overview of a High-Pressure Helium Flow Visualization Apparatus for Blanket Cooling Studies

Cooling of the fusion blanket first wall remains a significant challenge given the adverse conditions of heat and particle flux encountered near the plasma. Helium emerges as an attractive cooling candidate because of its chemical and neutronic inertness and separability from hydrogenic species (e.g. tritium). Because of the low thermal mass of helium, optimization of these coolant channels is warranted to provide high heat transfer performance at low pumping costs. Increasingly, computational fluid dynamics (CFD) simulations are employed to model and optimize these flow channels, and accompanying experimental data are needed to validate the predictions of these models. To provide the aforementioned experimental data, a high-pressure helium flow visualization upgrade has been designed for the Helium Flow Loop Experiment facility. This apparatus was built to American Society of Mechanical Engineers boiler and pressure vessel standards to withstand operating pressure of 4 MPa and mated to high-pressure glass windows. Seedless flow visualization is performed via high-speed background oriented schlieren (BOS), with image correlation used for time-resolved two-dimensional velocimetry at frequencies in excess of 60 kHz. Rectangular flow channel test articles are additively manufactured via laser powder bed fusion and installed into this visualization apparatus, with one-sided heating supplied by resistive heaters. In conclusion, the chosen test geometries were informed by prior CFD simulations, and the helium flow structures observed via BOS (detachment, recirculation, etc.) will be used for the validation of these accompanying models, in support of the design and optimization of blanket cooling channel configurations.

Helium flow↗
DOE OSTI2020

Ultrasonic Measurements of Temperature Distribution in Extreme Environments: Results of Power Plant Testing

The most hardened insertion sensors do not perform reliably in extreme environmental conditions. We address this problem by developing an ultrasonic thermometry system for the measurements of segmental temperature distributions (MSTD) in solid materials and, specifically, across containments of energy conversion processes. The MSTD approach uses an echogenically segmented ultrasound propagation path, structured to contain engineered or naturally occurring echogenic features. In pulse-echo mode, these features produce a train of echoes in response to an external pulse of ultrasonic excitation created and acquired by a transducer located outside the extreme environment. The delays between the echoes encode the information on the temperature distribution in the corresponding segments of the ultrasonic propagation path, which we use to reconstruct an unknown temperature profile. This note describes the preliminary results and initial experience in applying the developed MSTD ultrasonic thermometry system to the measurements of temperatures in a utility-scale 500MW coal-fired boiler.

John, Mason↗
DOE OSTI2021

Power Plant Testing of Ultrasonic Measurements of Temperature Distributions and Heat Fluxes to Heat Exchange Surfaces

Extreme environmental conditions are common in energy conversion applications, in which the most hardened insertion sensors often do not perform reliably for long. On the other hand, ultrasonic measurements can be acquired noninvasively, with sensitive components kept away from the damaging environment. We have previously developed the ultrasonic method for measuring the spatial distribution of temperatures in solid materials applicable when large thermal gradients are present. In the developed approach, we use the echogenically segmented ultrasound propagation path, structured to contain engineered or naturally occurring echogenic features, to produce a train of echoes in response to an external pulse of ultrasonic excitation. This paper outlines the testing results of this approach applied to the temperature distribution measurements to a waterwall of a 500 MW power-plant utility boiler. The validation results obtained over the prolonged power plant test show that the estimated temperature profile is correctly captured, and the measurement accuracy can be comparable with traditional insertion sensors, such as thermocouples. Overall, the testing has confirmed that the developed approach has matured to become an attractive alternative to conventional sensing in solving challenging problems of long-term temperature measurements in extreme environments. Heat fluxes and thermal stresses in the structure can then be characterized noninvasively using the measured temperature distribution as the basis.

Walton, Kenneth↗
DOE OSTI2021

A Minimum Creep Rate for 2-1/4Cr-1Mo Steel Consistent With the ASME Section III, Division 5 Rules

This technical note describes a minimum creep rate model for 2-1/4Cr-1Mo steel that is consistent with the current creep strain equation embedded in the ASME Boiler & Pressure Vessel Code Section III, Division 5, Subsection HB, Subpart B isochronous stress–strain curves. Minimum creep rate models for all the Section III, Division 5 Class A materials are required for the development of improved high temperature design methods. Of all the Class A materials, only 2-1/4Cr-1Mo does not have a readily identifying minimum creep rate term in the current isochronous stress–strain curve model.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Accelerated Creep Test Qualification of Creep-Resistance Using the Wilshire–Cano–Stewart Constitutive Model and Stepped Isostress Method

In this paper, a qualification of accelerated creep-resistance of Inconel 718 is assessed using the novel Wilshire–Cano–Stewart (WCS) model and the stepped isostress method (SSM) and predictions are made to conventional creep data. Conventional creep testing is a long-term continuous process; in fact, the ASME B&PV III requires that 10,000+ h of experiments must be conducted to each heat for materials employed in boilers and/or pressure vessel components. This process is costly and not feasible for rapid development of new materials. As an alternative, accelerated creep testing techniques have been developed to reduce the time needed to characterize the creep resistance of materials. Most techniques are based upon the time-temperature-stress superposition principle that predicts minimum-creep-strain-rate (MCSR) and stress-rupture behaviors but lack the ability to predict creep deformation and consider deformation mechanisms that occur for experiments of longer duration. The SSM has been developed, which enables the prediction of creep deformation response as well as reduce the time needed for qualification of materials. The SSM approach has been successful for polymer, polymeric composites, and recently has been introduced for metals. In this study, the WCS constitutive model, calibrated to SSM test data, qualifies the creep resistance of Inconel 718 at 750 °C and predictions are compared to conventional creep testing data. The WCS model has proven to make long-term predictions for stress-rupture, MCSR, creep deformation, and damage in metallic materials. The SSM varies stress levels after time interval adding damage to the material, which can be tracked by the WCS model. The SSM data is calibrated into the model and the WCS model generates realistic predictions of stress-rupture, MSCR, damage, and creep deformation. The calibrated material constants are used to generate predictions of stress-rupture and are postaudit validated using the National Institute of Material Science database. Similarly, the MCSR predictions are compared from previous studies. Finally, the creep deformation predictions are compared with real data and is determined that the results are well in between the expected boundaries. Material characterization and mechanical properties can be determined at a faster rate and with a more cost-effective method. This is beneficial for multiple applications such as in additive manufacturing, composites, spacecraft, and industrial gas turbines.

42 ENGINEERING↗
DOE OSTI2022

Novel Tube Design for Superheater Heat Exchanger Enabled Via Additive Manufacturing

Superheater tubes are critical boiler components that operate at relatively higher temperatures and pressure. Amongst the primary concerns for these tubes is the deposition of ash particles on the tube surface, leading to the reduced thickness of the tube due to material corrosion, consequently causing early creep failure of the component. In this research, a novel tube design has been proposed which resembles a teardrop or ogive shape to reduce the drag and concurrently improve the creep life of the superheater tubes. To administer the practicality of novel tubes, metal additive manufacturing (AM), for instance, laser-powder bed fusion (L-PBF), has been proposed. These unconventional designs were assessed and compared with the baseline circular tube design for mechanical design requirements (hoop stress and creep life) and the particle and flue gas flow characteristics around the differently shaped tubes. A thermomechanical finite element (FE) analysis was performed for hoop stress calculations. This study also emphasizes on effect of circumferential thermal variation on hoop stress distribution in tubes. Therefore, a detailed two-dimensional (2D) thermal simulation has been performed to report the circumferential thermal variation on the tube. A computational fluid dynamics (CFD) analysis coupled with particle tracing was performed for gas flow visualization and particle tracing around the proposed shapes and baseline circular-shaped tube design. The Schlieren optic setup was built and leveraged for qualitative validation of the proposed design. The complete design methodology established in the paper shows teardrop-shaped tubes better in terms of drag and creep life in contrast to the circular-shaped tube.

42 ENGINEERING↗
DOE OSTI2022

Design of an Additively Manufactured Recuperator With 800 °C Inlet Temperature for sCO2 Power Cycle Application

Abstract Recuperators with design temperatures at and above 800 °C can further increase the thermal efficiency of supercritical CO2 power cycles by enabling higher turbine exhaust temperatures. Mar-M247 is a well-suited nickel-based superalloy for high temperature service due to its high creep strength that prevents excessive material thickness being required for pressure containment. Additive manufacturing using a high-speed laser-directed energy deposition (L-DED) process presents a promising solution, with build trials demonstrating the ability to produce nonconventional flow channels for enhanced heat transfer. A design process is presented that includes aerothermal and mechanical evaluation to maximize performance within the constraints of the manufacturing process. A 2-D heat transfer network and pressure drop code allows prediction of flow distribution and its effect on overall thermal performance. Established literature correlations, along with CFD simulation, inform the prediction of heat transfer coefficients and friction factors for the flowpaths and enhancement features in the heat exchanger core. Mechanical evaluation using finite element analysis (FEA) modeling with the intent of the ASME Boiler & Pressure Vessel Code (BPVC) Section VIII, Div. 2 assesses the operational safety of the design. The detailed design features annular finned passages that take advantage of helical flow paths to distribute the flow from separated headers to shared heat transfer surfaces. Performance predictions for the recuperator at a 50 kW scale provide insights into the feasibility of the additively manufactured (AM) process to produce recuperators on a commercial scale that extend existing operating envelopes.

Engineering↗
DOE OSTI2023

Manufacturing and Hydro Testing of a 10 MWe sCO2 Axial Turbine

Abstract Supercritical CO2 (sCO2) power cycles designed for thermodynamic efficiencies above 50% push component designs into pressure and temperature combinations that approach the limits of American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code and ASME Piping Design Codes with Turbine inlet conditions near 250 bar and 715 °C. These design conditions which limit available materials to high nickel alloys are compounded by the high fluid densities of sCO2 at these conditions which result in very compact machinery at the 10 MWe class which are currently being developed for the DOE supercritical transformational electric power (STEP) program. Design of the STEP Turbine is complete with integrated lessons learned from a previous 1 MWth subscale demonstration of a high temperature 10 MWe Turbine designed under the DOE SunShot Program. Fabrication of the STEP Turbine is nearing completion with all housings and pressure containing components in hand. This paper provides a detailed look at design intentions and limitations for the pressurized sections of the main pressure casing and the fabrication of key turbine components. Additional discussion is provided regarding postfabrication inspection and acceptance of the casing for use after issues with casing welds were identified late in the fabrication process.

Engineering↗