Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “exchanger”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 397 records · Page 22
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Enhancing particle-to-sCO2 heat exchanger effectiveness through novel high-porosity metallic foams

In this project, a novel concept of Octet-shape based lattice frame material was developed for deployment in particle-to-sCO2 heat exchangers for CSP application. A comprehensive experimental and numerical program was performed to investigate and characterize the thermal and flow transport behavior in high porosity lattice frame material. The thermal properties include effective thermal conductivity and interstitial heat transfer coefficient and flow properties including permeability and inertial coefficient. Above quantities were determined for both air flow and heated particle flow through the porous channels which were representative of the hot channel in a typical counter flow heat exchanger. The cold side of the heat exchanger feature minichannels which are known to be very efficient in thermal transport. The goal of this project was to enhance the overall heat transfer coefficient (Up) on the hot side by introducing Octet-shape based lattice frame material through enhancement in effective thermal conductivity of the channel and through enhancement in the interstitial heat transfer coefficient.

14 SOLAR ENERGY↗
DOE OSTI2024

Al-Ce Alloy-Based Compact Heat Exchanger for Refrigerant Charge Reduction and Unprecedented Durability (CRADA NFE-21-08888 Final Report)

Oak Ridge National Laboratory and Eck Industries produced and characterized durable and corrosion resistant Al-Ce-Mg alloy-based heat exchanger. Eck Industries successfully casted Al-Ce-Mg heat exchanger. ORNL characterized reaction bonding between Al-2Ce-6Mg alloy and stainless-steel tube in a heat exchanger header. Metallurgical bonds were achieved between stainless steel tubes and Al-Ce-Mg alloy cast headers. ORNL performed corrosion testing on Al-Ce-Mg alloy/stainless steel tube reactive bond interface. In most cases no significant changes to the reactive bond morphology or compositional distribution were observed in the samples after exposure to acid for 267h acid.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Joining Study for Formed Plate Heat Exchangers (CRADA Final Report)

Plate heat exchangers (PHEs) have been used in numerous industrial applications, such as HVAC systems, power generation, transportation and manufacturing. The performance of plate heat exchangers is frequently undermined by corrosion, fouling, and scaling. These phenomena not only diminish heat transfer efficiency but also lead to increased operational costs, maintenance demands, and reduced equipment lifespan. In this project, the team addressed the widespread challenges of corrosion, fouling, and scaling, and explored alternative material solutions. While commonly used materials like stainless steel and titanium offer notable benefits, they can still experience corrosion under certain operating conditions. The advancement of new materials and surface engineering technologies, such as advanced coating, ceramics, composites materials, and high entropy alloys are promising for can help solve these issues, enable longer lifetime and high performance of plate heat exchangers.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2025

Sulfate Conversion of Reillex HPQ Anion Exchange Resin for Disposal (Interim Report)

This report describes preliminary data to validate the Savannah River Plutonium Processing Facility’s (SRPPF) flowsheet for conversion of used Reillex HPQ anion exchange resin from the nitrate form to the sulfate form. The nitrate form is an oxidizer and therefore does not meet acceptance criteria for disposal at the Waste Isolation Pilot Plant (WIPP). The purpose of this study is to develop data to support acceptance for this disposition pathway. Due to the challenges characterizing the nitrate concentration on solid resin, the data developed to date are based upon indirect analysis of the ion exchange column effluent by ion chromatography. These challenges are discussed and two methods for quantification of nitrate directly on the resin are recommended for further development: TGA-MS and permanganate digestion followed by IC. The resin used for this work was provided in the chloride form; this is the form in which resin is supplied by the manufacturer. However, it had to be converted to the nitrate form, which is the form that will be used in SRPPF’s ion exchange process, prior to use in the sulfate conversion experiments. The chloride-form resin was characterized. A lab-scale procedure for the conversion of Reillex HPQ resin from the chloride to nitrate form was validated. The nitrate-form resin was assessed for particle size and chloride concentration to ensure it met SRPPF’s facility specifications. The baseline sulfate conversion flowsheet was tested. However, nitrate was still detectable in the effluent after approximately 10 bed volumes of 1 M sodium sulfate had been passed through the resin bed. Additional experiments were performed to assess the effect of increasing the feed volume, reducing the flowrate, the use of 2 M sulfuric acid instead of sodium sulfate, and the use of irradiated resin. The sulfuric acid test was the only one which provided a nondetectable nitrate concentration (<0.002 M) in the effluent. Detectable nitrate in the column effluent suggests that nitrate is still present on the resin itself.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2026

Making Small-Volume Heat Pump Water Heaters Larger: A Design Framework for Integrated Phase Change Material Heat Exchangers

Those that use electricity for water heating, the majority use resistive elements rather than heat pump water heaters (HPWHs), the latter of which use 60-70% less energy than the former. One major barrier to wider HPWH adoption is the added equipment required, which prevents current 50-80-gallon tanks on the market from fitting into smaller utility closets sized for 30-40 gallons, such as those found in manufactured housing. Additionally, these smaller HPWHs tend to underperform relative to their larger counterparts. One solution that addresses both space and performance concerns is thermal energy storage, and in particular, phase change materials (PCMs). PCMs have been studied extensively in building envelope and HVAC systems, but remain a nascent technology in residential water heating. While water itself has a uniquely high energy storage capacity, PCMs have an even higher energy storage density, thus providing the potential to elevate the performance of 40-gallon HPWHs to that of 50-gallon or larger tanks. This research is part of a larger project that seeks to utilize thermal energy storage to enable decarbonized water heating in low-income communities. In this study, we outline the design process used to produce novel PCM heat exchangers for use in small-volume HPWH tanks, including the identification of design constraints and performance targets relevant to real-world applications. In order to ensure optimal PCM utilization and tank storage capacity, we focus here on co-maximizing surface area and PCM volume in the heat exchangers; therefore, this research targets triply periodic minimal surface (TPMS) lattices. TPMS lattices boast enhanced heat transfer capabilities compared to traditional heat exchanger geometries and offer highly tailorable designs; thus, they pair well with the growing field of additive manufacturing, or 3D printing. Starting with a suite of TPMS lattices, we demonstrate a systematic approach for narrowing down feasible designs that comply with identified constraints while meeting PCM performance objectives.

25 ENERGY STORAGE↗
DOE OSTI2025

SHOTEAM: Superalloy Heat exchangers Optimized for Temperature Extremes and Additive Manufacturability (Final Technical Report)

UCLA developed an extreme-condition heat exchanger technology targeted to ultra-high efficiency hybrid aviation power cycles. The heat exchanger targeted operation at 50 kW (thermal) at supercritical CO 2 pressures of 80 and 250 bar (1160 and 3626 psi) in hot and cold streams, respectively and at a hot-stream inlet temperature of 800°C (1472°F). A metallic superalloy capable of withstanding high temperature and pressure was used to fabricate a microtube shell-and-tube-based design supplemented with 3D-printed tube augmentations. The optimized design enhanced overall heat transfer while maintaining a small overall form factor and low weight. This class of heat exchanger could dramatically improve efficiency, power density, and cost effectiveness for new hybrid aviation power cycles, thus enabling economically feasible routes to air vehicle propulsion with substantially less CO 2 emissions to the environment.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2021

Two Dimensional Topology Optimization of Heat Exchangers with the Density and Level-Set Methods

We design heat exchangers using two topology optimization approaches: the density, i.e. volume fraction and level set methods. Our goal is to maximize the heat exchange between two fluids in separate channels while constraining the pressure drop across each channel. The heat exchanger is modeled with a coupled thermal-flow formulation. The flow is governed by an isothermal and incompressible Stokes-Brinkman equation and the heat transfer is governed by a convection-diffusion equation with high Peclet number. We solve one set of Stokes-Brinkman equations per fluid. Each Brinkman term in the flow equation serves to model the other phase as a solid, thereby preventing mixing. We first represent the solid and fluid phases using a volume fraction variable and apply a SIMP-like penalization in the Brinkman term to drive the optimization to a discrete design. The cost and constraint function derivatives are automatically calculated with the library pyadjoint and the optimization is performed by the Method of Moving Asymptotes. In a second optimization formulation, we use the level set approach to define the interface that separates the two fluids. Pyadjoint calculates the shape derivatives of the cost and constraint functions and the Hamilton-Jacobi advects the interface, allowing for topological changes. We present results in two dimensions and discuss the advantages and disadvantages of each approach.

42 ENGINEERING↗
DOE OSTI2022

Assessing the Oxidative Stability of Anion Exchange Membranes in Oxygen Saturated Aqueous Alkaline Solutions

While anion exchange membrane water electrolyzers show promise as a source of green hydrogen using low-temperatures and non-platinum group metal catalysts, many concerns must be addressed. A primary challenge for the development of high-performance anion exchange membrane water electrolyzers is the fabrication of a stable membrane that will be able to survive long-term stability test while maintaining high anion conductivity, which is a necessity for a durable water electrolyzer. This method will present a standardized protocol that can be used by researchers to assess the quality of their AEM materials and be able to provide insight into how materials may be degrading and how to improve the quality of AEMs. Using Mohr or Volhard titration to measure ion-exchange capacity, EIS to determine the ionic conductivity, NMR and FTIR to understand the extent of membrane degradation over time, and mechanical analyzers to determine the strength of their AEMs, this standardized protocol will guide researchers to determining and improving upon the long-term durability and performance of their AEM materials.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Optimization of Triply Periodic Minimal Surface Heat Exchanger to Achieve Compactness, High Efficiency, and Low-Pressure Drop

With advancements in additive manufacturing (AM) techniques, high-quality triply periodic minimal surface (TPMS) structures can now be produced. TPMS walled heat exchangers (HX) hold significant potential for industrial applications and are receiving increasing attention. This paper explores the impact of various TPMS design variables on flow and thermal performance to optimize TPMS heat exchangers for compactness, high efficiency, and low pressure drop. The design variables examined include the type of TPMS lattice, unit cell size, wall thickness, aspect ratio, TPMS orientation, and equivalent thickness. The study reveals that the flow and heat transfer performance of TPMS structures are significantly affected by these design variables. For the Gyroid, Diamond, and SplitP lattices, performance is nearly identical when the surface-to-volume ratio is kept constant. The average velocity of the fluid in the TPMS HX should be 0.3 m/s. The corresponding Re is between 300~800. Thin wall thickness, small equivalent thickness, and flat lattice configurations can significantly reduce pressure drop while maintaining the overall heat transfer coefficient. Additionally, the angle between the flow direction and TPMS orientation can increase pressure drop. Three aluminum heat exchangers were successfully printed using an AM machine, and testing results are comparable with theoretical prediction.

42 ENGINEERING↗
DOE OSTI2021

High-Resolution Spatio-Temporal Estimation of Net Ecosystem Exchange in Ice-Wedge Polygon Tundra Using In Situ Sensors and Remote Sensing Data

Land-atmosphere carbon exchange is known to be extremely heterogeneous in arctic ice-wedge polygonal tundra regions. In this study, a Kalman filter-based method was developed to estimate the spatio-temporal dynamics of daytime average net ecosystem exchange (NEEday) at 0.5-m resolution over a 550 m by 700 m study site. We integrated multi-scale, multi-type datasets, including normalized difference vegetation indices (NDVIs) obtained from a novel automated mobile sensor system (or tram system) and a greenness index map obtained from airborne imagery. We took advantage of the significant correlations between NDVI and NEEday identified based on flux chamber measurements. The weighted average of the estimated NEEday within the flux-tower footprint agreed with the flux tower data in term of its seasonal dynamics. We then evaluated the spatial variability of the growing season average NEEday, as a function of polygon geomorphic classes; i.e., the combination of polygon types—which are known to present different degradation stages associated with permafrost thaw—and microtopographic features (i.e., troughs, centers and rims). Our study suggests the importance of considering microtopographic features and their spatial coverage in computing spatially aggregated carbon exchange.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

Coupled Gas-Exchange Model for C4 Leaves Comparing Stomatal Conductance Models

Plant simulation models are abstractions of plant physiological processes that are useful for investigating the responses of plants to changes in the environment. Because photosynthesis and transpiration are fundamental processes that drive plant growth and water relations, a leaf gas-exchange model that couples their interdependent relationship through stomatal control is a prerequisite for explanatory plant simulation models. Here, we present a coupled gas-exchange model for C4 leaves incorporating two widely used stomatal conductance submodels: Ball–Berry and Medlyn models. The output variables of the model includes steady-state values of CO2 assimilation rate, transpiration rate, stomatal conductance, leaf temperature, internal CO2 concentrations, and other leaf gas-exchange attributes in response to light, temperature, CO2, humidity, leaf nitrogen, and leaf water status. We test the model behavior and sensitivity, and discuss its applications and limitations. The model was implemented in Julia programming language using a novel modeling framework. Our testing and analyses indicate that the model behavior is reasonably sensitive and reliable in a wide range of environmental conditions. The behavior of the two model variants differing in stomatal conductance submodels deviated substantially from each other in low humidity conditions. The model was capable of replicating the behavior of transgenic C4 leaves under moderate temperatures as found in the literature. The coupled model, however, underestimated stomatal conductance in very high temperatures. This is likely an inherent limitation of the coupling approaches using Ball–Berry type models in which photosynthesis and stomatal conductance are recursively linked as an input of the other.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2021

Advanced absorber heat integration via heat exchange packings

A rate-based model of an absorption column was developed and used to analyze several intercooling strategies utilizing “heat exchange packings.” These packings are capable of removing heat from the column and transferring it to a cooling fluid within the packing. For absorption of CO 2 into aqueous monoethanolamine under industrial conditions, intercooling via heat exchange packings placed along 10–20% of the column could reduce the column height by ~15%. The height of these columns was close to the minimum theoretical value, calculated by numerically optimizing the temperature profile. Effective intercooling could also be achieved by using the cool, rich solvent as the cooling fluid. This reduces the cooling load and facilitates recovery of waste heat. Heat exchange packings could also be used to redistribute heat within the column, reducing the column height with no net cooling load. However, this approach requires larger heat transfer coefficients than have been experimentally observed.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2020

Deactivation of Cu-Exchanged Automotive-Emission NH 3 -SCR Catalysts Elucidated with Nanoscale Resolution Using Scanning Transmission X-ray Microscopy

To gain insight into the underlying mechanisms of catalyst durability for the selective catalytic reduction (SCR) of NO x with an ammonia reductant, we employed scanning transmission X-ray microscopy (STXM) to study Cu-exchanged zeolites with the CHA and MFI framework structures before and after simulated 135 000-mile aging. X-ray absorption near-edge structure (XANES) measurements were performed at the Al K- and Cu L-edges. The local environment of framework Al, the oxidation state of Cu, and geometric changes were analyzed, showing a multi-factor-induced catalytic deactivation. In Cu-exchanged MFI, a transformation of Cu II to Cu I and Cu x O y was observed. We also found a spatial correlation between extra-framework Al and deactivated Cu species near the surface of the zeolite as well as a weak positive correlation between the amount of CuI and tri-coordinated Al. By inspecting both Al and Cu in fresh and aged Cu-exchanged zeolites, we conclude that the importance of the preservation of isolated Cu II sites trumps that of Brønsted acid sites for NH 3 -SCR activity.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2022

Data–driven and constrained optimization of semi–local exchange and nonlocal correlation functionals for materials and surface chemistry

Reliable predictions of surface chemical reaction energetics require an accurate description of both chemisorption and physisorption. Herein, we present an empirical approach to simultaneously optimize semi-local exchange and nonlocal correlation of a density functional approximation to improve these energetics. A combination of reference data for solid bulk, surface, and gas-phase chemistry and physical exchange-correlation model constraints leads to the VCML-rVV10 exchange-correlation functional. Owing to the variety of training data, the applicability of VCML-rVV10 extends beyond surface chemistry simulations. It provides optimized gas phase reaction energetics and an accurate description of bulk lattice constants and elastic properties.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Search for $t$-channel scalar and vector leptoquark exchange in the high-mass dimuon and dielectron spectra in proton-proton collisions at $\sqrt{s}=13$ TeV

A search for t-channel exchange of leptoquarks (LQs) is performed in dimuon and dielectron spectra using proton-proton collision data collected at $\sqrt{s}=13$ TeV with the CMS detector at the CERN LHC. The data correspond to an integrated luminosity of 138 fb −1 . Eight scenarios are considered, in which up or down quarks couple to muons or electrons via a scalar or vector LQ exchange, for dilepton invariant masses above 500 GeV. The LQ masses are probed up to 5 TeV, beyond a regime probed by previous pair-production and single-production searches. The differential distributions of dilepton events are fit to templates that model the nonresonant LQ exchange and various standard model background processes. Limits are set on LQ-fermion coupling strengths for scalar and vector LQ masses in the 1–5 TeV range at 95% confidence level, establishing stringent limits on first- and second-generation LQs.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2026

Actinium–DOTA coordination in water from hybrid ML/MM: Structure, free energies, and water-exchange pathways

Quantitative simulation of trivalent ƒ-block chelates in water remains challenging because bonded and non-bonded force-field models make different approximations for coordination structure, exchange dynamics, and ion–ligand interactions in highly charged systems. Here, we develop a hybrid machine-learning/molecular-mechanics (ML/MM) framework for Ac 3+ –DOTA in explicit solvent by training an E(3)-equivariant neural network potential (MACELES) on mechanically embedded QM/MM data for Ac aquo and Ac–DOTA species and coupling it to NAMD 2.14 with particle-mesh Ewald electrostatics. Nanosecond ML/MM trajectories remain numerically stable and preserve chelate integrity, yielding a compact DOTA inner shell with an inner-sphere water coordination number of CN Ac,O w ≈ 1.7 arising from a dynamic equilibrium between one- and two-water states (37.5% and 59.9% of frames; three waters 2.5%). A 5 ns potential of mean force shows two low-lying basins at CN Ac,O w ≈ 1 and CN Ac,O w ≈ 2. DFT end-state free energies are consistent with the ML/MM profile, and DFT minimum-energy paths provide a qualitative electronic-structure reference for the observed basin connectivity. State-resolved kinetics reveal picosecond water-exchange pathways that couple hydration changes to transient DOTA arm fluctuations, and training-set comparisons show that temperature-matched Ac–DOTA data optimize energy/force accuracy while more diverse solvated data improve charge prediction. Overall, the present hybrid ML/MM model provides a practical description of Ac 3+ –DOTA hydration thermodynamics and short-time exchange behavior in explicit water at MD-like cost.

Actinium↗
DOE OSTI2023

Adaptations for gas exchange enabled the elongation of lepidopteran proboscises

The extensive biodiversification of butterflies and moths (Lepidoptera) is partly attributed to their unique mouthparts (proboscis [Pr]) that can span in length from less than 1 mm to over 280mm in Darwin's sphinx moths. Lepi-doptera, similar to other insects, are believed to inhale and exhale respiratory gases only through valve-like spi-racles on their thorax and abdomen, making gas exchange through the narrow tracheae (Tr) challenging for the elongated Pr. How Lepidoptera overcome distance effects for gas transport to the Pr is an open question that is important to understanding how the Pr elongated over evolutionary time. Here, we show with scanning electron microscopy and X-ray imaging that distance effects on gas exchange are overcome by previously unreported micropores on the Pr surface and by superhydrophobic Tr that prevent water loss and entry. We find that the density of micropores decreases monotonically along the Pr length with the maxima proportional to the Pr length and that micropore diameters produce a Knudsen number at the boundary between the slip and transition flow regimes. By numerical estimation, we further show that the respiratory gas exchange for the Pr predominantly occurs via diffusion through the micropores. In conclusion, these adaptations are key innovations vital to Pr elongation, which likely facilitated lepidopteran biodiversification and the radiation of angiosperms by coevolutionary processes.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2021

An experimental study on dehumidification and regeneration performance of a new nonporous membrane-based heat and mass exchanger using an ionic liquid desiccant

As a promising alternative to inefficient vapor-compression-based air conditioning, liquid desiccant dehumidification uses a liquid desiccant in contact with the humid air absorbing the moisture. However, it has not gained much market share due to the issues related to the carryover, corrosion, fouling, and crystallization of liquid desiccant. The research has developed a new membrane-based exchanger, which uses a non-corrosive ionic liquid desiccant and nonporous tubular membranes to address these issues. As the second generation of the prototype, the new exchanger was tested at various operating conditions. According to the experimental data, when it is used in the dehumidification loop, the new membrane-based exchanger achieves a specific vapor transportation rate of 778.6 g/(h–m 2 ) and an average water vapor flux of 0.316 g/(h-m 2 -Pa), which is a significant improvement compared with the previous designs using nonporous membranes. It also achieved a comparable or even better dehumidification performance compared with the dehumidifiers that use porous membrane and conventional liquid desiccants. However, the regeneration performance is not as good as its dehumidification. It is mainly caused by the high operating temperature required in the regeneration loop. The experimental data and findings provide first-hand experimental data and enhance the understanding of advanced membrane-based ionic liquid desiccant systems.

42 ENGINEERING↗