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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 415 records · Page 23
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Removal of Iron from Pyrite-Rich Coal Refuse by Calcination and Magnetic Separation for Hydrometallurgical Extraction of Rare Earth Elements

In the metallurgical extraction of rare earth elements (REEs), the ratio of contaminant ions to REEs in the leachate dictates the cost and operational efficiency of the downstream processes. The current study investigated the potential iron contamination removal from the feed to the hydrometallurgical process by calcination followed by magnetic separation. The 2.20 specific gravity sink fraction of Baker coal seam coarse refuse was pulverized to finer than 180 μm, calcined at various temperatures, and separated into magnetic and non-magnetic fractions using a wet high-intensity magnetic separator at different field strengths. The untreated feed, calcined products, and their subsequent magnetic and non-magnetic fractions were subjected to acid leaching tests with 1.2 M sulfuric acid at 75 °C and 1% w/v solids concentration. The recovery of light and heavy rare earth elements (LREEs and HREEs, respectively) along with the concentration of common contaminant ions (Al, Ca, and Fe) were measured as output variables. The weight percent of magnetic material was maximized at approximately 29% by calcination at a temperature of 400 °C. Magnetic removal of this fraction using a field strength of 1.15 Tesla resulted in the rejection of 81% of the iron. Leaching of the magnetic fraction provided significantly higher Fe recovery relative to untreated feed material and the non-magnetic fraction. The non-magnetic fraction was subsequently calcined at 600 °C to dehydroxylate the clays and released the REE minerals in the same manner as the treatment of the original coarse refuse material. A comparison of the leachate elemental concentrations resulting from the leaching of both the calcined non-magnetic and original coarse refuse showed only a slight reduction in the iron content from the non-magnetic material. This finding combined with the REE loss in the magnetic fraction resulted in the conclusion that the magnetic removal step was unfavorable.

58 GEOSCIENCES↗
DOE OSTI2020

Produced Water Desalination via Pervaporative Distillation

Herein, we report on the performance of a hybrid organic-ceramic hydrophilic pervaporation membrane applied in a vacuum membrane distillation operating mode to desalinate laboratory prepared saline waters and a hypersaline water modeled after a real oil and gas produced water. The rational for performing “pervaporative distillation” is that highly contaminated waters like produced water, reverse osmosis concentrates and industrial have high potential to foul and scale membranes, and for traditional porous membrane distillation membranes they can suffer pore-wetting and complete salt passage. In most of these processes, the hard to treat feed water is commonly softened and filtered prior to a desalination process. This study evaluates pervaporative distillation performance treating: (1) NaCl solutions from 10 to 240 g/L at crossflow Reynolds numbers from 300 to 4800 and feed-temperatures from 60 to 85 °C and (2) a real produced water composition chemically softened to reduce its high-scale forming mineral content. The pervaporative distillation process proved highly-effective at desalting all feed streams, consistently delivering <10 mg/L of dissolved solids in product water under all operating condition tested with reasonably high permeate fluxes (up to 23 LMH) at optimized operating conditions.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

Mapping of a Novel Zero-Liquid Discharge Desalination System Based on Humidification–Dehumidification onto the Field of Existing Desalination Technologies

It is well-established that increasing demands for fresh water are paving the way for desalination technologies. However, this correlates with an increase in brine production whose treatment and disposal can be complicated and expensive. This paper presents a thermodynamic model to bound the operation and development of a novel Humidification–Dehumidification-based system featuring Zero-Liquid Discharge and off-grid capabilities. The model employs conservation laws to find feasible state points to meet a baseline operation of 10 kg/h of product water separated from a hypersaline feed stream with 100 g/kg salt concentration. The system incurs in a 1039 kWh/m3 energy intensity that can be supplied completely by an electric source or in combination with heating steam. Follow-up sensitivity analysis highlights the robustness of the system in handling variations of 25% in product flowrate and 75% in feed salinity, practically without incurring any additional energy demands. The proposed system operating costs between 72 USD/m3 and 96 USD/m3 are comparable to those of existing brine disposal techniques. Furthermore, an operational map of existing desalination technologies suggests a niche characterized by high recovery rates and high feed salinities that are generally unfulfilled by conventional desalination methods. Overall, the proposed system shows potential for off-grid hypersaline brine treatment. This study sets the stage for future development of physics-based and data-driven predictive models as the proposed system iterates into a pilot plant deployment.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Biomass yield potential, feedstock quality, and nutrient removal of perennial buffer strips under continuous zero fertilizer application

Perennial-based buffer strips have been promoted as having the potential for improving ecosystem services from riparian areas while producing biomass as livestock feed or as a bioenergy feedstock. Both biomass production and nutrient removal of buffer strips are substantially influenced by the vegetation types for the multipurpose perennial buffers. In this 2016–2019 study in western Illinois, two perennial cropping systems, including forage crops composed of cool-season grass mixtures (forage system) and bioenergy crops made up of warm-season grass mixtures (bioenergy system), were used to establish buffer strips for assessing biomass production, feedstock quality, nutrient removal, and buffer longevity. Treatments for this study reflecting agronomic practices included (1) two harvests occurring in summer (at anthesis) and fall (after complete senescence) and (2) one harvest in fall for the forage system (two-cut vs. one-cut forage) and (3) one fall harvest for the bioenergy system (one-cut bioenergy). Successively harvesting without any fertilizer input resulted in a yield decline in forage biomass over 3 years by approximately 30 % (6.3 to 4.4 Mg DM ha –1 (dry matter) with a rate of 1.0 Mg ha –1 yr –1 ) in the two-cut forage and by 35 % (4.9 to 3.2 Mg DM ha –1 with a rate of 0.9 Mg ha –1 yr –1 ) in the one-cut forage systems. The feed quality also decreased over the years by showing declined rates of 12.9 (crucial protein), 0.9 (calcium), 0.7 (copper), and 1.3 g kg –1 DM yr –1 (zinc). Empirical models predicted enteric CH 4 emissions from cattle ranged from 225.7 to 242.6 g per cow per day based on the feed nutritive values. In contrast, bioenergy biomass yield increased by 27 % from 4.9 to 6.7 Mg DM ha –1 with a consistent quality (cellulose of ~ 397.9 g kg –1 ; hemicellulose of ~ 299.4 g kg –1 ), corresponding to the increased total theoretical ethanol yield from 1.8 × 10 3 to 2.4 × 10 3 L ha –1 (~ 33 % increase). Annual nutrient removals of N, P, K, Ca, and Mg were significantly higher in the forage systems (e.g., two-cut: 52.6–106.9 kg N ha –1 ; one-cut: 44.5–84.1 kg N ha –1 ) than those in the bioenergy system (e.g., 25.9–34.4 kg N ha –1 ); however, the removal rate declined rapidly over 3 years (e.g., ~ 49 % reduction) as the annual biomass yield declined in the forage systems. This on-farm field study demonstrated the potential of the perennial crop used as buffer strip options for biomass production and buffer sustainability at the edge of the field.

09 BIOMASS FUELS↗
DOE OSTI2026

Automatic Volume Balancing for Online Refueling in Molten Salt Reactor Simulations with SCALE

This work introduces recently implemented capabilities in the SCALE code system’s TRITON reactor physics sequence that improve molten salt reactor (MSR) modeling: (1) a volume balancing option, which automatically balances the volumes of the fed material with a corresponding material removal to maintain fixed mixture volumes in the neutron transport model and accurate densities, and (2) continuous feed from mixtures, which enables users to define material feed streams directly from salt mixture definitions rather than individual nuclides. The new capabilities were demonstrated via SCALE/TRITON simulations of two representative MSR concepts. Simulations of the 180 MWth molten chloride fast reactor—a system with a fixed fuel salt volume in the reactor core—applied continuous refueling with fresh fuel salt. The results confirm approximately constant reactivity when the new volume balancing capability is used. Additionally, excellent agreement with a manual feed-and-drain method for volume balancing further verified the new implementation. Simulations of the 400 MWth EIRENE reactor, an integral MSR in which the salt volume may grow over time within the reactor core, demonstrated the capability to represent growing salt volume within the TRITON depletion calculation. Compared with reference solutions, the results show consistent trends in reactivity and isotopic evolution, confirming that these new user-friendly capabilities provide accurate, physically consistent approaches for modeling MSRs in SCALE.

Elzohery, Rabab [ORNL] (ORCID:0000000160043633)↗
DOE OSTI2024

Reverse Osmosis Simulation Data

This dataset consists of computational fluid dynamics (CFD) output for various spacer configurations in a feed-water channel in reverse osmosis (RO) applications. Feed-water channels transport brine solution to the RO membrane surfaces. The spacers embedded in the channels help improve membrane performance by disrupting the concentration boundary layer growth on membrane surfaces. Refer to the "Related Work" resource below for more details. This dataset considers a feed-water channel of length 150mm. The inlet brine velocity and concentration are fixed at 0.1m/s and 100kg/m3 respectively. The diameter of the cylindrical spacers is fixed as 0.3mm and six varying inter-spacer distances of 0.75mm, 1mm, 1.5mm, 2mm, 2.5mm, and 3mm are simulated. The dataset comprising the steady, spatial fields of solute concentration, velocity, and density near each spacer is placed in the folder corresponding to the spacer configuration considered. We run two sets of CFD simulations and include the outputs from both sets for each configuration: (1) with a coarser mesh, producing low-resolution (LR) data of spatial resolution 20x20, and (2) with a finer mesh, producing high-resolution (HR) data of spatial resolution 100x100. These data points can be treated as images with the quantities of interest as their channels and can be used to train machine learning models to learn a mapping from the LR images as inputs to the HR images as outputs.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2020

Design and Fabrication of the Mu2e Cryogenic Distribution System

The muon-to-electron conversion (Mu2e) experiment at Fermilab will be used to search for the charged lepton flavor-violating conversion of muons to electrons in the field of an atomic nucleus. The Mu2e experiment is currently in the design and construction stage and is expected to begin operations in 2022. The Mu2e experiment uses four large superconducting solenoid magnets including a Production Solenoid (PS), an Upstream and Downstream Transport Solenoid (TSu and TSd) and a Detector Solenoid (DS). This paper will focus on the cryogenic distribution system for these four solenoid magnets. Liquid helium will be supplied from two re-purposed Tevatron satellite refrigerators. A large cryogenic distribution box (DB) is located in the Mu2e building to distribute the required cryogens to each of the four solenoid magnets. Each solenoid magnet will have a dedicated transfer line and cryogenic feed box (FB). The solenoid magnets each require two liquid helium circuits and two liquid nitrogen circuits. The most unique feature about this cryogenic system is that the assemblies for the start of the superconducting portion of the power leads are mounted in feed boxes that are in the range of 23 m to 31 m away from the solenoid magnets. The cryogenic feed boxes are located remotely to provide protection from radiation damage and high magnetic fields. The power leads are NbTi superconducting cable stabilized with high conductivity aluminum. The 6061-T6 aluminum grade was selected for the transfer line piping so that the piping would thermally contract at the same rate as the power lead. A major concern for this transfer line is that a small helium leak could create an electric discharge arc due to the Paschen effect. This paper includes a description of the design features and testing done to ensure that the power leads are protected from the Paschen effect while still being adequately cooled to liquid helium temperatures.

43 PARTICLE ACCELERATORS↗
DOE OSTI2020

Single-reactor conversion of ethanol to 1-/2-butenes

A simplified processes for producing desired chemicals such as butenes from feedstock mixtures containing ethanol. In one set of embodiments this is performed in a single step, wherein a feed containing ethanol in a gas phase is passed over an acidic metal oxide catalyst having a transition metal dispersion of at least 5% on a metal oxide support. The ethanol content of the feedstock mixture may vary from 10 to 100 percent of the feed and in those non-eat applications the ethanol feed may contain water.

09 BIOMASS FUELS↗
DOE OSTI2020

Pressure balancing of anode and cathode in a fuel cell system

A fuel cell system includes a fuel cell having an anode configured to receive anode feed gas and output anode exhaust, and a cathode configured to receive cathode feed gas and output cathode exhaust. The system further includes a pressurizing assembly downstream from the anode and an oxidizer downstream from the anode. The cathode feed gas is the anode exhaust that has been compressed in the pressurizing assembly and reacted with air in the oxidizer.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2020

Heat dissipation systems with hygroscopic working fluid

In various embodiments, the present invention relates to heat dissipation systems including a hygroscopic working fluid and methods of using the same. In various embodiments, the present invention provides a method for heat dissipation using a hygroscopic working fluid. The method can include transferring thermal energy from a heated process fluid to the hygroscopic working fluid in a process heat exchanger, to form a cooled process fluid. The method can include condensing liquid from a feed gas on a heat transfer surface of a feed gas heat exchanger in contact with the cooled process fluid, to form a cooled feed gas, the heated process fluid, and a condensate. The method can include dissipating thermal energy from the hygroscopic working fluid to a cooling gas composition with a fluid-air contactor. The method can include transferring moisture between the hygroscopic working fluid and the cooling gas composition with the fluid-air contactor. The method can include adding at least part of the condensate to the hygroscopic working fluid.

Martin, Christopher Lee↗
DOE OSTI2020

Oxy-fuel combustion and power generation system

Integration of an oxyfuel combustion boiler at elevated pressures and a heat exchanger is achieved to produce carbon dioxide by feeding flue gas comprising carbon dioxide and water from the oxyfuel combustion boiler to a direct contact cooler column wherein water is condensed at a temperature of 0 to 10° C. lower than its dew point; feeding a portion of the condensed water from the direct contact cooler column to the oxyfuel combustion boiler; feeding a portion of the carbon dioxide from the direct contact cooler column to the oxyfuel combustion boiler; and recovering a portion of the carbon dioxide from the direct contact cooler column.

Alekseev, Alexander↗
DOE OSTI2021

Method of separating components of a gas

A method is disclosed for separating components of a gas. A feed gas stream is passed into a vessel. The feed gas stream includes methane, carbon dioxide, and water. The feed gas stream is cooled in the vessel such that a portion of the methane and a portion of the carbon dioxide condense and a portion of the water desublimates, resulting in a product stream and a depleted gas stream exiting the vessel.

Baxter, Larry↗
DOE OSTI2021

Method of separating components of a gas

The disclosure provides a method for separating components of a gas. A feed gas stream is cooled in a first vessel. The feed gas stream includes methane, water, carbon dioxide, and Natural Gas Liquids. The feed gas stream is cooled in a first vessel. A portion of the water condenses to form a primary liquid stream, resulting in a first depleted gas stream, which is cooled in a second vessel. A portion of the NGLs condense to form a secondary liquid stream, resulting in a second depleted gas stream, which is cooled in a condensing exchanger. A first portion of the methane condenses to form a liquid methane stream, resulting in a third depleted gas stream, which is cooled in a third vessel. A portion of the carbon dioxide condenses, desublimates, or condenses and desublimates as a final product stream, also resulting in a fourth depleted gas stream.

Baxter, Larry↗
DOE OSTI2021

On the Phase Grouping Mechanism for a Magnetron Coherent Oscillation

CW magnetrons, developed for industrial heaters, but driven by an injection-locking signal were suggested to power Superconducting RF (SRF) cavities due to higher efficiency and lower cost of generated RF power per Watt than traditionally used RF sources (klystrons, IOTs, solid-state amplifiers). When the magnetrons are intended to feed Room Temperature (RT) cavities, the injected phase or frequency locking signal may provide required phase or frequency stability of the accelerating field. However, when the magnetron RF sources are intended to feed high Q-factor SRF cavities, the sources must be controlled in phase and power in a wide bandwidth to compensate parasitic phase and amplitude modulations caused by microphonics. In dependence on parameters of magnetron and the injection-locking signal one can choose regime most suitable for feeding SRF cavities, enabling magnetron almost coherent oscillation at the wide bandwidth of control. A novel approach considering magnetrons as quasi-coherent or coherent RF generators enables choosing the tube parameters and operation most suitable for various SRF accelerators.

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

Heat exchangers fabricated by additive manufacturing, related components, and related methods

A method of forming at least a component of a heat exchanger comprises introducing a feed material comprising a first portion including a matrix material and a second portion including a sacrificial material on a surface of a substrate, exposing at least the first portion to energy to form bonds between particles of the matrix material and form a first thickness of a structure, introducing additional feed material comprising the first portion over the first thickness of the structure, exposing the additional feed material to energy to form a second thickness of the structure, and removing the sacrificial material from the structure to form at least one channel in the structure. Related heat exchangers and components, and related methods are disclosed.

van Rooyen, Isabella J.↗
DOE OSTI2022

Coolant delivery via an independent cooling circuit

An embodiment of an independent cooling circuit for selectively delivering cooling fluid to a component of a gas turbine system includes: at least one coolant feed channel fluidly coupled to a supply of cooling fluid; and an interconnected circuit of cooling channels, including: an interconnected circuit of cooling channels embedded within an exterior wall of the component; an impingement plate; and a plurality of feed tubes connecting the impingement plate to the exterior wall of the component and fluidly coupling a supply of cooling fluid to the interconnected circuit of cooling channels; wherein the cooling fluid flows through the plurality of feed tubes into the interconnected circuit of cooling channels only in response to a formation of a breach in the exterior wall of the component that exposes at least one of the cooling channels.

42 ENGINEERING↗
DOE OSTI2022

Coolant delivery via an independent cooling circuit

A coolant delivery system for a component of a gas turbine system includes: a plurality of independent circuits of cooling channels embedded within an exterior wall of the component, each independent circuit of cooling channels including a plurality of headers and a plurality of feed tubes fluidly coupling the plurality of headers to a supply of cooling fluid; and an impingement plate connected to the exterior wall of the component by the plurality of feed tubes of the independent circuits of cooling channels, wherein, in each of the plurality of independent circuits of cooling channels, the cooling fluid flows through the plurality of feed tubes and the plurality of headers into the circuit of cooling channels only in response to a formation of a breach in the exterior wall of the component that exposes at least one of the cooling channels of the circuit of cooling channels.

Hafner, Matthew Troy↗
DOE OSTI2023

System and method of making an enhanced cast iron crankshaft

A method and system for manufacturing a cast iron crankshaft for a vehicle are provided. The system comprises a molding unit arranged to form a negative sand cast mold of the cast iron crankshaft. The mold comprising at least one molded cavity having a pattern with dimensions of the cast iron crankshaft. The system further comprises a feeding mechanism comprising a riser having a connector through which molten metallic material flows to the cast mold. The feeding mechanism feeds the molten metallic material at a riser connection angle in the at least one mold cavity. The riser connection angle corresponds to a connector modulus. The connector modulus is 20% greater than a cast modulus. The riser geometry corresponds to a riser modulus. The riser modulus is 20% greater than the connector modulus. The system further comprises a furnace, a cooling area, a separation unit, a controller and a power source.

Wang, Liang↗