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All sources NASA NTRS DOE OSTI

DOE OSTI2020

Thermal Analysis of a Superconducting Undulator Cryostat for the APS Upgrade

The Advanced Photon Source Upgrade includes four 4.8-m-long superconducting undulator (SCU) cryostats, each containing two planar undulator NbTi magnets up to 1.9 m long. The cooling is provided by six cryocoolers arranged in three thermal circuits. The magnets are indirectly cooled with LHe penetrating through channels in the magnet cores. This 4 K circuit, which also includes a LHe tank, is cooled by five 4 K cryocooler 2nd stages. A beam vacuum, which is thermally isolated from the magnets, is cooled by one 10 K cryocooler 2nd stage. A thermal shield and warm parts of current leads are cooled by the 1st stages of all six cryocoolers. This paper presents an ANSYS-based thermal analysis of the new SCU cryostat including all thermal circuits. The benchmarked thermal conductance between the cryocooler cold heads and the LHe tank are used in the calculations as well as the measured cryocooler load lines. The model predicts temperatures in the system, total 4 K heat loads, and excess cooling power for various operational modes of the undulator.

Shiroyanagi, Y.↗

DOE OSTI2014

Effects of Multiple Drying Cycles on High-Burnup PWR Cladding Alloys

The purpose of this research effort is to determine the effects of canister/cask vacuum drying and storage on radial hydride precipitation in high-burnup (HBU) pressurized water reactor (PWR) cladding alloys during cooling for a range of peak drying-storage temperatures, internal gas pressures, and hoop stresses. The HBU PWR cladding alloys have a wide range of hydrogen contents and varying hydride morphology after in-reactor service. Radial hydrides are a potential embrittlement mechanism for HBU cladding subjected to hoop-stress loading, which may be significant during normal cask transport. Ring compression tests (RCTs), which simulate pinch-type loading at grid spacers, are used to determine cladding ductility as a function of RCT temperature and the ductile-to-brittle transition temperature (DBTT). Previous tests were conducted with pressurized and sealed cladding rodlets heated to 400°C (the NRC ISG-11, Rev. 3, limit for all fuel burnups under normal conditions of storage and short-term loading operations) and cooled slowly at 5°C/h. Following this drying-storage simulation, the DBTT for HBU M5 ® decreased from 80°C to 70°C to <20°C as the peak hoop stress decreased from 140 MPa to 110 MPa to 90 MPa. Under similar drying-storage conditions, the DBTT for HBU ZIRLO™ decreased from 185°C to 125°C to 20°C to <20°C as the peak cladding hoop stress decreased from 140 MP to 110 MPa to 90 MPa to 80 MPa. These tests were conducted with a single heating-cooling cycle as simulation of the vacuum drying process with one drying cycle. (ISG-11, Rev. 3 allows <10 drying cycles, with cladding temperature variations that are less than 65°C each.)

Billone, M. C.↗

NASA NTRS2003

Continuous Cooling from 10 K to 4 K Using a Toroidal ADR

Future large infrared space telescopes will require cooling to 4K to achieve background limited performance for submillimeter wavelengths. These observatories will require lifetimes of many years and will have relatively large cooling requirements making stored helium dewars impractical. We have designed and are building an adiabatic demagnetization refrigerator (ADR) for use in cooling relatively large loads (10- 100 mW) at 4K and rejecting that heat to a cryocooler operating at 1 OK. Cryocoolers below 1 OK have poor thermodynamic efficiency and ADRs can operate in this temperature range with an efficiency of 75% of Carnot or better. Overall, this can save as much as 2/3 of the input power required to operate a 4K cryocooler. The ADR magnet consists of 8 short coils wired in series and arranged in a toroid to provide self shielding of its magnetic field. This will save mass (about 30% of the mass or about 1.5 kg in our small version, higher percentages in higher cooling power, larger versions) that would have been used for passive or active shields in an ordinary solenoid. The toroid has a 100 mm outer diameter and will produce an approximately 3T average field. In the initial demonstration model the toroid coils will be wound with ordinary NbTi wire and operated at 4K. A second version will then use Nb3Sn wire to provide complete 10K operation. As a refrigerant for this temperature range we will use either GdLiF4 or GdF3 crystals, pending tests of these crystals' cooling capacity per field and thermal conductance. Preliminary indications are that these materials are superior to GGG. We will use gas gap heat switches to alternately connect the toroid to the cold load and the warm heat sink. A small continuous stage will maintain the cold end at 4K while the main toroid is recycled.

DiPirro, Michael J.↗

DOE OSTI2017

FY 17 Q1 Commercial integrated heat pump with thermal storage milestone report

The commercial integrated heat pump with thermal storage (AS-IHP) offers significant energy saving over a baseline heat pump with electric water heater. The saving potential is maximized when the AS-IHP serves coincident high water heating and high space cooling demands. A previous energy performance analysis showed that the AS-IHP provides the highest benefit in the hot-humid and hot-dry/mixed dry climate regions. Analysis of technical potential energy savings for these climate zones based on the BTO Market calculator indicated that the following commercial building market segments had the highest water heating loads relative to space cooling and heating loads education, food service, health care, lodging, and mercantile/service. In this study, we focused on these building types to conservatively estimate the market potential of the AS-IHP. Our analysis estimates maximum annual shipments of ~522,000 units assuming 100% of the total market is captured. An early replacement market based on replacement of systems in target buildings between 15 and 35 years old was estimated at ~136,000 units. Technical potential energy savings are estimated at ~0.27 quad based on the maximum market estimate, equivalent to ~13.9 MM Ton CO2 emissions reduction.

42 ENGINEERING↗

NASA NTRS1982

Experimental and analytical determination of gear tooth temperatures with oil jet lubrication

Gear tooth average and instantaneous surface temperatures were measured with a fast response infrared radiometric microscope, while operating at arious speeds, loads and oil jet pressures. Increased oil jet pressure had a significant effect on both average and peak surface temperatures at all test conditions, increasing the speed at constant load and increasing the load at constant speed causes a significant rise in average and peak surface temperatures of gear teeth. A gear tooth temperature analysis was conducted by a finite element method combined with a calculated heat input and oil jet impingment depth with estimated heat transfer coefficients based on the experimental data. It is concluded that oil jet pressures required for adequate cooling at high load and speed conditions must be high enough to get full penetration depth of the teeth.

Townsend, D. P.↗

NASA NTRS1980

Comparison of elastic and elastic-plastic structural analyses for cooled turbine blade airfoils

Elastic plastic stress strain states in cooled turbine blade airfoils were calculated by three methods for the initial takeoff transient of an advanced technology aircraft engine. The three analytical methods compared were a three dimensional elastic plastic, finite element analysis, a three dimensional, elastic, finite element analysis, and a one dimensional, elastic plastic, beam theory analysis. Structural analyses were performed for eight cases involving different combinations of mechanical and thermal loading on impingement cooled airfoils with and without leading edge film cooling holes. The von Mises effective total strains at maximum takeoff computed from the elastic and elastic plastic finite element analyses agreed with 9 percent for rotating airfoils and 28 percent for stationary airfoils with the elastic results on the conservative side.

Kaufman, A.↗

DOE OSTI2024

Developing Near Optimal Control Sequences for Chiller Plants with Water-side Economizers: A Case Study in a Warm and Marine Climate

Various advanced control sequences for chiller plants with water-side economizers (WSE) have been proposed in literature, but the optimization of those controls is limited. It is possible to maximize energy savings by developing near-optimal control sequences, which are dependent on several factors such as the load profile. To address these gaps, we first identify an advanced control sequence and three key control parameters for chiller plants with WSE. Next, optimizations are performed to minimize energy consumption for seven combinations of control parameters. A chiller plant with WSE system in a warm and marine climate is studied and two load profiles are considered. The system and controls are modeled using the Modelica Buildings library. The results show optimizing the selected control parameters can reduce energy consumption by up to 11% depending on the load profile. Specifically, optimizing the cooling tower efficiency threshold in the condenser water reset control can significantly reduce energy savings for the variable load profile by efficiently shifting the load from the cooling tower to the chiller. This paper provides practical guidance for developing near-optimal control sequences for chiller plant with WSE systems considering impacts such as the load profile.

chiller plant↗

NASA NTRS1952

Analysis of Coolant-flow Requirements for an Improved, Internal-strut-supported, Air-cooled Turbine-rotor Blade

An analytical evaluation of a new typ An analytical evaluation of a new type of air-cooled turbine-rotor-blade design, based on the principle of submerging the load-carrying element in cooling air within a thin high-temperature sheel, indicates that this principle of blade design permits the load carrying element to be operated at considerably lower temperature than that of the enveloping shell. Comparison with an air-cooled shell-supported air-cooled blade has greater potentiality to withstand increased stresses that can be anticipated in future engines.

Schramm, Wilson B↗

NASA NTRS2023

NASA Team Develops a Test Article to Demonstrate “Zero Boil-Off” Storage of Liquid Hydrogen via Cryocoolers and a Two-Stage Cooling Approach

Funded by NASA’s Technology Demonstration Mission Program and managed by the Cryogenic Fluid Management Portfolio Project, a NASA team is developing a test article to demonstrate the “zero boil-off” storage of liquid hydrogen using active cooling (cryocoolers) and a two-stage cooling approach. The current state of the art for storage of liquid hydrogen on-orbit is on the order of hours while future missions may require storage for months or even years. To enable such extended storage durations, “near zero” propellant loss, or “zero boil-off”, must be achieved. This may be accomplished with the implementation of “near zero” leakage components, a high performing suite of passive technologies to minimize the environmental heat loads, and active cooling via cryocoolers to intercept and remove heat from the propellant tanks and associated structure. Of course, with any cryogenic vehicle and mission, a mass and power trade should be conducted to determine if it is indeed feasible to carry the additional dry mass associated with active cooling, or if one could simply carry additional propellants to accommodate propellant loss which is typically not an option for a long duration mission.

Hydrogen Storage↗

DOE OSTI2019

Assessing the Potential of Active Insulation Systems to Reduce Energy Consumption and Enhance Electrical Grid Services

Building envelopes today act as passive systems in a dynamic environment. Traditional energy-saving efforts have mainly tried to improve the performance of building envelope systems by increasing thermal resistance to a set value that reduces energy flow. However, changes in weather and indoor conditions often lead to situations in which a low thermal resistance would decrease energy use. The optimization of thermal resistance that is triggered by changes in temperature, solar radiation, or availability of energy from renewable sources is currently not possible. Controllable active insulation systems (AISs), in which the thermal resistance of the insulation material can be dynamically controlled within a certain range, can expand the capabilities of the building envelope. With AISs the building envelope is no longer only a passive barrier between indoors and outdoors; instead, heat transfer can be controlled. Moreover, when AISs are combined with the thermal mass in the envelope system, these can act as thermal batteries that can be loaded and unloaded on demand. To quantify the benefits of AISs, a literature study of active insulation and achievable thermal conductivity ranges, thermal simulation models, and control logics was performed. Based on this literature study, a simulation model was developed to control the thermal resistance of insulation materials. A methodology to assess the potential of active insulation systems to reduce energy use and enhance electrical grid services was established and applied to identify ideal implementation scenarios for active insulation systems. A significant reduction of total building energy consumption for heating and cooling was found in all climate zones. The savings for the slab-on-ground DOE residential prototype building for eight selected cities in different climate zones range from 4069 kBtu to 8433 kBtu. Depending on the control cooling during peak load hours in Los Angeles could be reduced by more than 80% without a negative impact on thermal comfort conditions.

Antretter, Florian↗

DOE OSTI2018

Capturing the Competing Influence of Thermal and Mechanical Loads on the Strain of Turbine Blade Coatings via High Energy X-rays

This paper presents findings of synchrotron diffraction measurements on tubular specimens with a thermal barrier coating (TBC) system applied by electron beam physical vapor deposition (EB-PVD), having a thermally grown oxide (TGO) layer due to aging in hot air. The diffraction measurements were in situ while applying a thermal cycle with high temperature holds at 1000 °C and varying internal air cooling mass flow and mechanical load. It was observed that, during high temperature holds at 1000 °C, the TGO strain approached zero if no mechanical load or internal cooling was applied. When applying a mechanical load, the TGO in-plane strain (e22) changed to tensile and the out of plane TGO strain (e11) became compressive. The addition of internal cooling induced a thermal gradient, yielding a competing effect, driving the e22 strain to compressive and e11 strain to tensile. Quantifying TGO strain variations in response to competing factors will provide a path to controlling the TGO strain, and further improving the lifetime assessment and durability design strategies for TBC systems.

36 MATERIALS SCIENCE↗

DOE OSTI2017

Thermally Stratified Compression Ignition: A new advanced low temperature combustion mode with load flexibility

We introduce a new advanced combustion mode, called Thermally Stratified Compression Ignition (TSCI), which uses direct water injection to control both the average temperature and the temperature distribution prior to ignition, thereby providing cycle-to-cycle control over the start and rate of heat release in Low Temperature Combustion (LTC). Experiments were conducted to fundamentally understand the effects of water injection on heat release in LTC. Our results show that water injection retards the start of combustion due to the latent heat of vaporization of the injected water. Furthermore, for start of water injection timings between 20 and 70 degrees before top dead center, combustion is significantly elongated compared to without water injection. The 10–90% burn duration with 6.6 and 9.0 mg of water per cycle was 77% and 146% longer than without water injection, respectively. Forced thermal stratification result from a direct water injection which reduces the heat release rate by local evaporative cooling. Finally, the load limits with and without water injection were determined experimentally. Without water injection, the load range was 2.3–3.6 bar gross IMEP. By using water injection to control heat release, the load range in TSCI was 2.3–8.4 bar gross IMEP, which is a range expansion of over 350%. These results demonstrate that direct water injection can provide significant improvements to both controllability and the range of operability of LTC, thereby resolving the major challenges associated with HCCI.

20 FOSSIL-FUELED POWER PLANTS↗

NASA NTRS1994

Cooled Panel With Thermostats In All Passages

Simple shape-memory-alloy or bimaterial thermostatic valve incorporated in each passage of multiple-passage cooled panel, according to proposal. Thermostatic valves all set to same opening/closing temperature, so they regulate flows in all passages to equalize or nearly equalize temperature across panel in presence of transient, nonuniform surface heating. Concept beneficial in application in which overheating causes damage and both overcooling and excessive circulation of coolant occurs in absence of regulation if cooling capacity of panel made large enough to handle peak heat load. Potential applications include cooled structures for advanced hypersonic aircraft and engines.

Blosser, Max L.↗

NASA NTRS1984

Advanced passive radiator for spaceborne cryogenic cooling

A novel design to improve the cooling capability of spaceborne cryogenic passive radiators is described. The design is based on the use of lightweight angled radiation shields, low-conductance structural supports, and a separate detachable launch-support system to reduce the parasitic heat leaks from the warm spacecraft to the cold radiator. The effectiveness of this design is demonstrated by thermal-vacuum-chamber experiments which indicate that the angled-radiation-shield assembly has an effective emittance that is an order of magnitude lower than that of the best multilayer insulation used in flight. Performance predictions based on the experiments and analytical model indicate that an advanced passive-radiator design based on this technology would be between 10 and 57% of the size and 10 and 36% of the mass of the best state-of-the-art passive radiators and would make lower temperatures (< 60 K) and larger heat loads practical. The cooling requirements of many new spaceborne instruments could be accommodated by application of this new passive-radiator design.

Steven Bard↗

DOE OSTI2023

Evaluation of thermostat location for multizone commercial building performance

In multi-zone buildings, it is often found that a single shared thermostat controls more than one conditioned zones. Although these shared zones are supposed to have similar thermal needs (e.g., cooling and heating load), in reality, they are not mainly due to different orientations, sizes of windows, occupancy, space types, etc. This can cause unnecessary energy waste or thermal discomfort for the occupants. How to quantify this impact in multizone buildings remains a research gap. Therefore, this study aims to evaluate the impact of different sensor (i.e., thermostat) locations for multizone commercial buildings through a comprehensive modeling study. Here, two different scenarios for the sensor locations were selected to evaluate the impact in terms of energy and thermal comfort. The scenario (1) is that one to five sensors distributed among the five zones, but the sensor readings from selected zones will be used for no-sensor zones, which is no-mean sensor scenario. The scenario (2) is that one to five sensors distributed among the five zones, but the average temperature from the shared zones will be used for each of the shared zones, which is a mean sensor scenario. The uncertainty analysis was performed for different sensor location scenarios.(a)The major findings from an energy perspective, for scenario (1), the differences of cooling energy go as high as 17% more or 12% less, compared with the baseline. For heating energy consumption, the discrepancies go as high as 51% more or 52% less, compared with baseline. For site energy consumption, the discrepancies go as high as 3.2% more or 3.2% less, compared with baseline. For fan energy consumption, the discrepancies go as high as 3.2% more or as low as 1.0% less, compared with baseline. For scenario (2), the discrepancies of cooling energy go as high as 3% more, or 0.5% less, compared with the baseline. For heating energy consumption, the discrepancies, are go as high as 10.1% more or as low as 3.0% less, compared with baseline. For site energy consumption, the discrepancies go as high as 1.3% more or 0.3% less, compared with baseline. For fan energy consumption, the discrepancies go as high as 3.1% more or as low as 1.0% less, compared with baseline.(b) In terms of the indoor thermal comfort, for the no-mean-sensor scenarios, the discrepancies of unmet hours for cooling mode can be as high as 1,200 h, compared with the baseline. The discrepancies of unmet hours for heating mode can be as high as 740 h, compared with the baseline. For the mean-sensor scenarios, the discrepancies of unmet hours for cooling mode can be as high as 750 h, compared with the baseline. The discrepancies of unmet hours for heating mode can be as high as 50 h, compared with the baseline.

42 ENGINEERING↗

DOE OSTI2015

Climate Control Load Reduction Strategies for Electric Drive Vehicles in Warm Weather

Passenger compartment climate control is one of the largest auxiliary loads on a vehicle. Like conventional vehicles, electric vehicles (EVs) require climate control to maintain occupant comfort and safety, but cabin heating and air conditioning have a negative impact on driving range for all electric vehicles. Range reduction caused by climate control and other factors is a barrier to widespread adoption of EVs. Reducing the thermal loads on the climate control system will extend driving range, thereby reducing consumer range anxiety and increasing the market penetration of EVs. Researchers at the National Renewable Energy Laboratory have investigated strategies for vehicle climate control load reduction, with special attention toward EVs. Outdoor vehicle thermal testing was conducted on two 2012 Ford Focus Electric vehicles to evaluate thermal management strategies for warm weather, including solar load reduction and cabin pre-ventilation. An advanced thermal test manikin was used to assess a zonal approach to climate control. In addition, vehicle thermal analysis was used to support testing by exploring thermal load reduction strategies, evaluating occupant thermal comfort, and calculating EV range impacts. Through stationary cooling tests and vehicle simulations, a zonal cooling configuration demonstrated range improvement of 6%-15%, depending on the drive cycle. A combined cooling configuration that incorporated thermal load reduction and zonal cooling strategies showed up to 33% improvement in EV range.

33 ADVANCED PROPULSION SYSTEMS↗

NASA NTRS2023

A New Multi-Method Assessment of Stratospheric Sulfur Load From the Okmok II Caldera-Forming Eruption of 43 BCE

The 43 BCE eruption of Okmok Volcano has been proposed to have had a significant climate cooling impact in the Northern Hemisphere. In this study, we quantify the climate cooling potential of the Okmok II eruption by measuring sulfur concentration in melt inclusions (up to 1,606 ppm) and matrix glasses and estimate a total of 62 ± 16 Tg S released. The proportion reaching the stratosphere (2.5%–25%, i.e., 1.5–15.5 Tg S) was constrained by physical modeling of the caldera-collapse eruption. Using the NASA Goddard Institute for Space Studies E2.2 climate model we found a linear response between cooling and stratospheric sulfur load (0.05–0.08°C/Tg S). Thus, the 1–2°C of cooling derived from proxy records would require 16–32 Tg sulfur injection. This study underscores the importance of combining approaches to estimate stratospheric S load. For Okmok II, we find all methods are consistent with a range of 15–16 Tg S.

volcano-climate interaction↗

DOE OSTI2017

Automatic generation and simulation of urban building energy models based on city datasets for city-scale building retrofit analysis

Buildings in cities consume 30–70% of total primary energy, and improving building energy efficiency is one of the key strategies towards sustainable urbanization. Urban building energy models (UBEM) can support city managers to evaluate and prioritize energy conservation measures (ECMs) for investment and the design of incentive and rebate programs. This paper presents the retrofit analysis feature of City Building Energy Saver (CityBES) to automatically generate and simulate UBEM using EnergyPlus based on cities’ building datasets and user-selected ECMs. CityBES is a new open web-based tool to support city-scale building energy efficiency strategic plans and programs. The technical details of using CityBES for UBEM generation and simulation are introduced, including the workflow, key assumptions, and major databases. Also presented is a case study that analyzes the potential retrofit energy use and energy cost savings of five individual ECMs and two measure packages for 940 office and retail buildings in six city districts in northeast San Francisco, United States. The results show that: (1) all five measures together can save 23–38% of site energy per building; (2) replacing lighting with light-emitting diode lamps and adding air economizers to existing heating, ventilation and air-conditioning (HVAC) systems are most cost-effective with an average payback of 2.0 and 4.3 years, respectively; and (3) it is not economical to upgrade HVAC systems or replace windows in San Francisco due to the city's mild climate and minimal cooling and heating loads. Furthermore, the CityBES retrofit analysis feature does not require users to have deep knowledge of building systems or technologies for the generation and simulation of building energy models, which helps overcome major technical barriers for city managers and their consultants to adopt UBEM.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗