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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 OSTI2022

Experimental Studies of Graphene-Coated Polymer Electrolyte Membranes for Direct Methanol Fuel Cells

The two main technical limitations of direct methanol fuel cells (DMFCs) are the slow kinetic reactions of the methanol oxidation reaction (MOR) in the anode and the crossing over of unreacted methanol through the proton exchange membrane (PEM). It is a common practice to use Nafion membranes as PEMs, which have high ion exchange capacity. However, Nafion-based membranes also have high fuel permeability, decreasing fuel utilization, and reducing the potential power density. This article focuses on using graphene-coated (Gr-coated) PEMs to reduce fuel crossover. Protons can permeate across graphene, and thus, it can be employed in various devices as a proton conductive membrane. Here, we report the efficiency of Gr-coated Nafions. We tested performance and crossover at three different temperatures with four different fuel concentrations and compared it to a Nafion PEM that underwent the same test conditions. We found that the adhesion of Gr on to PEMs is insufficient for prolonging fuel cell operation, resulting in Gr delamination at high temperatures and higher fuel crossover values compared to lower temperature testing. Furthermore, the results for 7.5M methanol fuel show a reduction of up to 25% in methanol crossover, translating to a peak power density that increases from 3.9 to 9.5 mW/cm 2 when using a Gr-coated PEM compared to a Nafion PEM at 30 °C.

25 ENERGY STORAGE↗
DOE OSTI2022

HTS Dipole Magnet Model for the Persistent Current Operation

Recent advances in the fabrication of high-temperature superconducting (HTS) coils allow the design of superconducting accelerator magnets that work in a persistent current mode. Many various, rather low-field magnets in particle accelerators operate in the DC current mode. Fermilab designed, fabricated, and tested an HTS dipole magnet model that has 20-mm air gap and a magnetic field up to 0.5 T. The magnet has a primary copper coil that for a short period pumps the energy in the short-circuited secondary HTS coil. Here, the current paper presents the design, fabrication, and testing of this magnet at liquid-nitrogen temperature.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2023

A reduced order sulfuric acid decomposition model for a nuclear-powered hybrid sulfur cycle

A reduced order model of sulfuric acid decomposition within a bayonet chemical reactor was developed to support the U. S. Department of Energy Integrated Energy System program, and address the lack of knowledge in scaling and integration for joint chemical and nuclear processes. Sulfuric acid decomposition within a bayonet reactor was modeled to provide chemical and thermodynamic data relevant to advanced nuclear reactor-driven integrated energy systems based on desired operational scale and operational conditions. The temperature range required for high-temperature advanced nuclear reactor integrated energy systems, 750-850 °C, was shown to produce reasonable agreement (within a few percent relative error) with past models and experimental data, and yielded good efficiency results for bayonet reactor operations. The results of the reduced order model agreed with previous work from Savannah River National Labs within a maximum of 3.4% error on the decomposition of sulfur trioxide, and on previous Hybrid Sulfur flowsheets from Gorensek and Summers that showed operational temperature, pressure, and composition ranges for efficiency which made the Hybrid Sulfur cycle competitive with water electrolysis. Here, the agreement with previous high-fidelity models provided a framework for future Integrated Energy System grid evaluations with an advanced nuclear reactor and large-scale hydrogen production using a mathematical model to represent chemical operations.

08 HYDROGEN↗
DOE OSTI2022

Methyl Carbamate-Lithium Salt Deep Eutectic Electrolyte for Lithium-Ion Batteries

Deep eutectic electrolytes (DEEs) represent a burgeoning field in electrolytes for energy storage applications. Compared to the more conventionally studied Li-ion electrolyte systems, these electrolytes offer numerous advantages, such as high ion concentration, costs, lower temperature operation, and safety. In this work, the formation of a novel eutectic electrolyte based on lithium salts and methyl carbamate was reported. These DEEs were formed via mixing lithium salts and low-cost methyl carbamate at ratios varying from 1:2 to 1:5 (mol:mol). Here, the DEE formed from methyl carbamate and lithium hexafluorophosphate (LiPF 6 ) at a 1:5 molar ratio generated a 4V stability window and a 25°C conductivity of up to 3.16E –3 S cm –1 . The DEE formed from methyl carbamate and lithium bis(trifluoromethane)sulfonimide (LiTFSI) at a 1:5 molar ratio generated a 3.2 V stability window and a 25°C conductivity of up to 2.87E –3 S cm –1 . The LiPF 6 DEE also demonstrated a discharge capacity of 128 mAh g –1 after 50 cycles with 93% discharge capacity retention at moderate cycling rates of 0.5C in a lithium titanate (LTO)/lithium iron phosphate (LFP) full cell. These results demonstrate the potential for methyl carbamate to generate eutectics from lithium salts and offer alternative electrolytes for use in low-temperature Li-ion battery applications.

25 ENERGY STORAGE↗
DOE OSTI2026

Insights from a coupled thermo-hydro-mechanical analysis of a layered high-temperature thermal energy storage reservoir

Coupled thermal-hydraulic-mechanical (THM) modeling is applied to investigate the performance of a seasonal high-temperature aquifer thermal energy storage operation based on data and conditions from current site investigations at the Geostorage Forsthaus pilot project in Bern (Switzerland). The model includes subhorizontal sand lenses of various lengths and dips that are embedded in a low permeability clay matrix. Thermal energy storage is simulated by seasonal injection and withdrawal of hot (up to 90 °C) water from a main well, with reservoir pressure regulated by two auxiliary wells at a distance of about 70 m from the main well. The results show how targeted injection into deeper permeable storage formations, along with active deep well pressure control, can effectively minimize geomechanical impact and the potential risk of damaging subsurface storage and sealing formations, or even surface facilities. With such pressure control, the subsurface mechanical responses are dominated by thermal strain and stress, which can be monitored with subsurface fiber optics. The study demonstrates how coupled THM modeling can be applied for the design of a safe and efficient thermal energy storage operation, and how subsurface fiber optic monitoring can be applied for performance confirmation, allowing for more confident operational forecasting.

Rutqvist, Jonny↗
DOE OSTI2023

Aqueous buffer solution-induced crystallization competes with enzymatic depolymerization of pre-treated post-consumer poly (ethylene terephthalate) waste

In this paper, the complex relationship between kinetics and substrate morphology during enzymatic depolymerization of melt processed poly(ethylene terephthalate) (PET) is explored and the effects of competing transformations are analyzed. Extruded PET substrates from post-consumer recycled PET (RPET) bottles flakes subjected to enzymatic depolymerization are examined to reveal increases in crystallinity from ~10% post-extrusion to >30% after 3 days of depolymerization as well as increases in glass transition temperature (T g ) from ~66°C to > 80°C. Further investigation into this behavior shows that post-extrusion RPET substrates do not exhibit changes in crystallinity when subjected to dry annealing at 65°C in an oven over 7 days, but they do experience annealing in depolymerization buffer solution with no enzymes at 65°C within 3 days. This difference may be attributed to plasticization of PET in the presence of water, also known as solvent induced crystallization. The impact of this plasticized annealing behavior is demonstrated by subjecting RPET substrates to increasing enzyme-to-substrate loads. As enzyme load increases, overall conversion of substrates increases despite crystallinity also increasing to similar levels regardless of the initial enzyme loading. The competition between depolymerization and crystallization suggests that the rate at which PET substrates are depolymerized at the operational temperature is integral to achieving high conversion to monomeric product. This, in turn, also suggests that savings from lowered enzyme loadings may be more detrimental than helpful in pursuing the most cost-effective recycling systems.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Diverse electron carriers drive syntrophic interactions in an enriched anaerobic acetate-oxidizing consortium

Abstract In many anoxic environments, syntrophic acetate oxidation (SAO) is a key pathway mediating the conversion of acetate into methane through obligate cross-feeding interactions between SAO bacteria (SAOB) and methanogenic archaea. The SAO pathway is particularly important in engineered environments such as anaerobic digestion (AD) systems operating at thermophilic temperatures and/or with high ammonia. Despite the widespread importance of SAOB to the stability of the AD process, little is known about their in situ physiologies due to typically low biomass yields and resistance to isolation. Here, we performed a long-term (300-day) continuous enrichment of a thermophilic (55 °C) SAO community from a municipal AD system using acetate as the sole carbon source. Over 80% of the enriched bioreactor metagenome belonged to a three-member consortium, including an acetate-oxidizing bacterium affiliated with DTU068 encoding for carbon dioxide, hydrogen, and formate production, along with two methanogenic archaea affiliated with Methanothermobacter_A. Stable isotope probing was coupled with metaproteogenomics to quantify carbon flux into each community member during acetate conversion and inform metabolic reconstruction and genome-scale modeling. This effort revealed that the two Methanothermobacter_A species differed in their preferred electron donors, with one possessing the ability to grow on formate and the other only consuming hydrogen. A thermodynamic analysis suggested that the presence of the formate-consuming methanogen broadened the environmental conditions where ATP production from SAO was favorable. Collectively, these results highlight how flexibility in electron partitioning during SAO likely governs community structure and fitness through thermodynamic-driven mutualism, shedding valuable insights into the metabolic underpinnings of this key functional group within methanogenic ecosystems.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2022

Status of the PIP-II Cryoplant

The Proton Improvement Plan-II (PIP-II) is an essential upgrade to the Fermilab accelerator complex featuring a new 800-MeV Superconducting Radio-Frequency (SRF) linear accelerator (Linac). The Linac contains 23 SRF cryomodules with the SRF cavities operating at 2 K, a high temperature thermal shield at 40 K and low temperature intercepts at 4.5 K. The PIP-II cryoplant will provide the necessary cooling for the cryomodules and the cryogenic distribution system interconnecting cryoplant and cryomodules. This paper describes the evolution of the PIP-II cryoplant conceptual design and specifications, including the expected heat loads, required cooling features and the integrated design. The cryoplant capacity margin analysis and fast cool-down mode will also be discussed.

43 PARTICLE ACCELERATORS↗
DOE OSTI2021

Historical Context and Perspective on Allowable Stresses and Design Parameters in ASME Section III, Division 5, Subsection HB, Subpart B

In the 1970s, the U.S. Nuclear Regulatory Commission (NRC) issued Regulatory Guide (RG) 1.87 (Rev 1, June 1975) to provide interim licensing guidelines to aid applicants in implementing the 10 CFR Part 50 requirements with respect to American Society of Mechanical Engineers (ASME) Boiler Pressure and Vessel Code (BPVC) Class 1 components operating at elevated temperatures for high-temperature gas-cooled reactors, liquid-metal fast-breeder reactors, and gas-cooled fast-breeder reactors. RG 1.87 referenced ASME Code Case 1592 for materials and design and Code Cases 1593, 1594, 1595, and 1596 for fabrication and installation, examination, testing, and overpressure protection, respectively.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Production of Fischer-Tropsch Synfuels at Nuclear Plants

A case study analysis was performed to evaluate nuclear-powered synthetic fuel production in the midwestern United States (U.S.). A Fischer-Tropsch (FT) fuel synthesis plant design was used as the basis for the analysis. The FT plant design was configured to produce a product slate consisting of diesel fuel, jet fuel, and motor gasoline blend stocks from carbon dioxide (CO 2 ) and hydrogen (H 2 ) feedstocks. The CO 2 feedstock for the FT plant was assumed to be sourced from biorefineries in the region around a Midwest light water reactor (LWR) nuclear power plant (NPP). The analysis specifies that power from the LWR is used to produce H 2 via high-temperature steam electrolysis and to operate the FT synfuel production plant. Capital costs were estimated for the FT plant while capital costs for the electrolysis plant were based on previous Idaho National Laboratory (INL) studies. In addition to labor and maintenance costs for the FT and electrolysis plants, operating costs also include the costs for CO 2 feedstock transport. An analysis was performed to determine the cost of transporting CO 2 from the distributed biorefinery sources to the centralized fuel synthesis plant as a function of the synfuel plant capacity and corresponding CO 2 demand. The primary revenue streams are associated with sales of the synthetic fuel products. The synthetic fuel products will likely follow the same market trends as the conventional fuel products. The synfuel price data was thus based on projections made by the U.S. Energy Information Administration (EIA) 2021 Annual Energy Outlook (AEO) for conventional fuel products minus federal and state taxes, as well as marketing and distribution costs. The economic analysis also considered cases that included and excluded revenues from the 2022 Inflation Reduction Act (IRA) clean hydrogen production tax credit (PTC) of $\$ $3.00/kg for the first ten years of operation. The economic analysis calculated the net present value (NPV) for cases involving steady-state synfuel production for comparison with the NPV for a business-as-usual case in which NPP continues to sell only electric power to the grid. A synfuel production “Reference Case” was considered in addition to sensitivity cases in which the plant capacity, electricity price, and synthetic fuel product prices were perturbed. The synfuel production Reference Case considered a scenario in which the electrolysis and synfuel plants utilized a combined electrical load of 1000 megawatt electrical (MWe) from the LWR with the balance of the LWR power output being sold to the electric grid. The economic analysis suggests that the synfuel production Reference Case evaluated in this analysis would lead to considerable economic potential for near-term deployment of a nuclear-based synfuel production plant. Specifically, the economic analysis suggests that the deployment of a 1000 megawatt (MW) nuclear-powered synfuel plant could result in a NPV increase of approximately $\$ $1.7 billion for a case with no clean synfuel price premium relative to conventional petroleum fuels when accounting for the additional revenues from the 2022 IRA clean hydrogen PTCs of $\$ $3/kg. Sensitivity analysis was performed to evaluate the effect of perturbation of selected model input parameters on the NPV for the synfuel production Reference Case. The sensitivity analysis indicates that the plant capacity has the largest impact on the differential NPV, with a smaller synfuel production capacity resulting in a decrease in revenue when a larger fraction of the power from the NPP is sold to the grid and a smaller fraction of the power is used to produce synthetic fuel products. The synfuel product pricing has the next largest impact on the differential NPV, with lower synfuel prices resulting in decreased NPV from decreased synfuel sales revenue while higher synfuel prices result in increased NPV from increased synfuel sales revenue. Electricity pricing has a smaller effect on the NPV than the fuel sales price since, in the Reference Case, most of the energy from the NPP is used for synfuel production and a smaller amount of the system revenues are associated with electrical power sales. However, the electricity price sensitivity does indicate that the Synfuel Integrated Energy System (IES) would have a greater NPV than the business-as-usual case (e.g., grid power sales only) when electricity market prices are low, suggesting that synfuel production could provide a strategy for decreasing the economic risks to NPPs posed by a loss of revenues attributed to falling electricity market prices.

10 SYNTHETIC FUELS↗
DOE OSTI2025

Kinetic and Mechanistic Understanding of Boron-Containing Catalysts for the Production of Light Olefins through Selective Oxidation

In recent years, an abundance of natural gas obtained from shale deposits has created opportunities for the US chemical industry to establish new and more efficient processes for the production of chemical intermediates and polymers. For example, the replacement of petroleum-derived naphtha as a to shale-derived ethane as feedstocks has made the production of ethylene/polyethylene less costly. However, this shift in feedstock has led to lower production of propylene from steam crackers, and new “on-purpose” light olefin production technologies have been implemented to bridge the gap between propylene supply and demand. The most important of these processes is direct propane dehydrogenation (PDH), but catalyst deactivation and high temperatures lead to high capital and operating costs. Oxidative dehydrogenation of propane (ODHP) is an efficient alternative to PDH, but high selectivity to CO2 from previous metal oxide catalyst prevents implementation. Hexagonal boron nitride (hBN) and other boron-containing materials have been recently developed as highly selective catalysts for both ODHP and oxidative cracking, surpassing previous systems. Much is still unknown in regard to the mechanism and the dynamic surface changes that occur under reaction conditions. This research project aims to combine in situ/operando spectroscopic investigation and kinetic studies to elucidate the interplay between the proposed gas-phase mechanism and the surface structures on the working catalyst. These insights will be leveraged to create a framework for optimizing reaction conditions and material synthesis for the next generation of boron-containing selective oxidation catalysts.

02 PETROLEUM↗
DOE OSTI2025

Development of a Pronghorn Model of the High Temperature Engineering Test Reactor: Preliminary Results from Loss of Forced Cooling #3 [Slides]

This presentation contains results from a Pronghorn model of the High Temperature Engineering Test Reactor (HTTR) operated by the Japan Atomic Energy Agency. The model was used to simulate a loss of forced cooling (LOFC) experiment. This presentation contains preliminary results from a standalone thermal hydraulics model of this LOFC test and some discussion of the results compared to data

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗
DOE OSTI2020

Analysis of the Impurity MgOHCl in Molten Chloride Salts Toward its Electrochemical Removal from CSP Plants During Operation

The work presented here is a study of the impurity MgOHCl in molten chloride salts, toward the eventual goal of electrochemically removing it from operational molten-chloride-based concentrating solar power (CSP) plants.1,2 Implementation of molten chloride salts as a heat transfer fluid is among the most promising pathways for decreasing the levelized cost of energy (LCOE) of CSP systems because its high thermal stability allows higher operating temperatures, and thus, greater efficiency. However, this impurity - formed when MgCl2 salts are exposed to air and moisture - cause significant corrosion of containment alloys.1 Therefore, we have developed and validated in a laboratory setting: 1) a method for the formation of MgOHCl for controlled impurity spike in molten salt for its further sensing, evaluation, and reduction; 2) evaluated its diffusion in the molten salt, and 3) began assessing its electrochemical properties. Our findings allow us to propose solutions for efficiently and instantly removing MgOHCl from an operational CSP plant.

concentrated solar power↗
DOE OSTI2024

Advances in Molecular Beam Epitaxy Growth of Ultra-Wide Bandgap Ga2O3 Based Alloys

Gallium oxide (Ga2O3) is an emerging ultra-wide bandgap semiconductor material that has attracted attention for its potential to outperform existing SiC and GaN based devices operating at high breakdown voltages and high temperature. Isovalent alloying of In and Al in Ga2O3 provides the ability to engineer bandgap energy and strain of the material. Alloying with Al increases the bandgap energy and the theoretically achievable Baliga's figure of merit, a key measure of a material's ultimate performance limits for high power switching devices. Alloying with In introduces compressive strain and can be used to counteract the tensile strain of Al incorporation. The resulting (AlxGa1-x-yIny)2O3 alloy can be lattice-matched to commercially available Ga2O3 wafers and has a tunable bandgap energy greater than that of Ga2O3, 4.76 eV. Such lattice-matched material can be grown arbitrarily thick without the detrimental effects of elastic strain and relaxation, making it suitable for high voltage diodes and transistors. However, efforts to synthesize isovalent alloys are complicated by their tendency to phase separate into corundum Al2O3 or bixbyite In2O3. Literature reports of the quaternary (AlxGa1-x-yIny)2O3 are limited to <1% unintentional indium incorporation in In-catalyzed (AlxGa1-x)2O3. The primary limitation to quaternary growth is the limited incorporation of indium at elevated growth temperatures. This limited incorporation is due to both the volatility of indium oxide and Al and Ga cation exchange reactions which replace indium in In2O3. We report on the development of a novel high-throughput molecular beam epitaxy (MBE) technique to screen the growth conditions for the ternary alloy (InyGa1-y)2O3, and the application of these findings to the first successful synthesis of phase pure monoclinic (AlxGa1-x-yIny)2O3 by MBE. By leveraging the unique sub-oxide chemistry of Ga2O3 and in-situ monitoring of crystal properties by reflection high-energy electron diffraction (RHEED), a cyclical growth and etch-back method is developed and applied to rapidly characterize the (InyGa1-y)2O3 growth space. This cyclical method provides approximately 10x increase in experimental throughput and up to 46x improvement in Ga2O3 substrate utilization. Appropriate growth conditions for monoclinic (InyGa1- y)2O3 are identified by machine learning analysis of RHEED patterns and targeted growths are characterized ex-situ to confirm improved In incorporation. These growth conditions are then combined with established (AlxGa1-x)2O3 growth conditions to grow quaternary (AlxGa1-x-yIny)2O3 with Al mole fractions ranging from 1.4% - 24.4% and In mole fractions ranging from 3.1% to 15.5%. The chemical and optical properties of the alloys are investigated by XRD, XPS, and spectroscopic ellipsometry. A lattice-matched (AlxGa1-x-yIny)2O3 alloy is examined by 4D-STEM and the chemical and physical uniformity of Al and In incorporation are discussed.

alloy↗
DOE OSTI2024

Ultrahigh Performance Metallic Turbine Blades for Extreme Environments

In ULTIMATE Phase-I, The Boeing Company and Alloyed Inc. aimed to produce ultrahigh performance metallic extreme environment turbine blades with a base blade alloy capable of inert operation at 1300C, and a maximum coated blade operating temperature up to 1800C. High-performance structural designs for extreme service conditions place additional demands on the present material capability and can potentially outpace the current state-of-the-art in the alloy design space and metal processing. As a part of exploration and adoption of novel concepts for material maturation, the team explored a series of capable base novel refractory complex concentrated alloy (RCCA) compositions and potential powder enhancements. Advanced manufacturing processes, with a focus on laser powder bed fusion additive manufacturing (AM) and powder metallurgy (PM) approaches, were applied to consolidate new alloys and for near net shape processing of blades from the base RCCA.

Yousefiani, Ali↗
DOE OSTI2026

Mechanical Behavior of Neutron Irradiated Refractory Multi-Principal Element Alloys Processed via Spark Plasma Sintering

The search for advanced materials capable of withstanding the extreme conditions of Generation IV reactors is a critical area in materials science research. These reactors operate under severe environments, including high temperatures, corrosion, stress, and irradiation damage. Consequently, there is a need for innovative alloy systems to ensure the reliability and longevity of proposed Generation IV reactor components. Refractory multi-principal-element alloys (RMPEA) have emerged as a promising candidate due to their exceptional properties. These alloys, characterized by their composition of multiple principal elements in near-equiatomic ratios, exhibit superior resistance to irradiation damage, reduced void swelling, enhanced microstructural stability, and minimal irradiation-induced hardening. While initial studies on RMPEAs have shown promising results, most research has been limited to thin films, nanocrystalline microstructures, and ion irradiation, which do not accurately represent the behavior of bulk materials. To address this gap, our research focused on the neutron irradiation of bulk RMPEAs. We aim to conduct comprehensive post-irradiation examinations (PIE) of RMPEAs irradiated at the Advanced Test Reactor at Idaho National Laboratory. The RMPEAs were synthesized using spark plasma sintering (SPS) with mechanically alloyed metallurgical powder. The RMPEA specimens are a MoNbTi alloy system with additions of -Zr, and -ZrV. Furthermore, PIE consisted of mechanical testing and advanced materials characterization. The mechanical testing consisted of sub-sized tensile testing, micro- and nano- indentation. Microstructural characterization included scanning electron microscopy and transmission electron microscopy. Mechanical testing coupled with advanced microscopy techniques provides insight into phase morphology and its effects on the mechanical properties of the RMPEA specimens. The results indicate that both pristine and irradiated RMPEA specimens exhibited brittle behavior during tensile testing, which can be attributed to their heterogeneous microstructure. The SPS manufacturing process did not include any post treatment, which resulted in a heterogeneous microstructure. Energy-dispersive X-ray spectroscopy revealed the presence of intermetallic such as laves phases within the microstructure. Specifically, Ti-rich precipitates were observed in the MoNbTi specimen, while Mo-rich precipitates were found in the MoNbTiZrV specimen. Nano-hardness testing of pristine samples showed that the laves phases exhibited higher hardness values compared to the matrix phase, suggesting that precipitate hardening is likely the dominant hardening mechanism in these specimens. The results from this work will be used to build a finite element model to predict mechanical behavior of future MPEA compositions. Thus, enabling for a streamlined approach to developing novel MPEAs for the nuclear industry.

36 - MATERIALS SCIENCE↗
DOE OSTI2021

Creep-fatigue Behavior and Damage Accumulation of a Candidate Structural Material for Concentrating Solar Power Solar Thermal Receiver (Final Technical Report)

Creep-fatigue deformation is an important consideration for a thermal receiver in Concentrating Solar Power systems due to the constant static stress or pressure, diurnal cycling, and elevated service temperatures required for efficient operation. An accurate description of the creep-fatigue behavior, not available for five of the six candidate materials, is important for assessment of preliminary designs. This project has provided a detailed analysis of the creep-fatigue behavior and damage accumulation of Alloy 740H, a candidate structural material for a CSP solar thermal receiver to address a critical knowledge barrier for receiver designs identified in the CSP Gen3 Demonstration Roadmap. This project was divided in to three tasks, split between two general categories: Experimental and design methodology. Tasks 1 and 3, relating to the collection of data on Alloy 740H plate and sheet forms, respectively, were performed at the Idaho National Laboratory and used as input to Task 2, the development of design methodology performed at Argonne National Laboratory. Experimental work covered limited tensile and creep testing to fill gaps in available data that is currently available and to demonstrate how the plate of Alloy 740H tested in this work compared to historical data. A more substantial testing program for fatigue and creep-fatigue was performed, with particular emphasis on creep-fatigue as there is little available data and it is necessary to understand the creep-fatigue interaction and develop related design models. This effort includes the development of rules for the design of solar receiver components against high temperature creep-fatigue and ratcheting failure modes. The ASME Code rules for high temperature nuclear components was used to the basis of the method but adjustments will be made to reflect the generally shorter, diurnal operating cycles of thermal receivers and the relative consequences of failure, comparing nuclear to solar components. This work has provided guidance for the design of components for concentrating power facilities operating at high temperatures and undergoing high, secondary thermal stresses relative to the applied primary pressure stress. The design rules were developed for the design of Generation 3 CSP tubular receivers manufactured from Alloy 740H, but are generally applicable to a wide range of component types undergoing similar loads. Procedural design rules for components to be used in conjunction with the 2019 edition of the ASME Boiler & Pressure Vessel Code and the corresponding design data for Alloy 740H have been developed. A commentary describing the rationale behind the design rules and the data underlying the design material properties, as well as an extensive set of worked sample problems detailing the application of the rules to CSP components were developed as a part of this project, with a separate report covering these aspects in detail and included in the Appendix of this report.

14 SOLAR ENERGY↗
DOE OSTI2023

Enabling residential heating decarbonization through hydronic low-temperature thermal distribution using forced-air assistive devices

Space heating represents approximately one-tenth of the United States’ energy use and has a breadth of potential for emission reduction. An element of space heating, hydronic heat distribution methods, use water supply temperatures up to 82.2 °C (180 °F). However, this operating temperature can be incompatible with high-efficiency heat generation systems, which typically provide heating temperatures of up to 60 °C (140 °F). In this work, a low-cost retrofit solution is developed using experimentally validated computational tools by incorporating an airflow distributor that preferentially directs the airflow from a fan to enhance heat transfer over the finned-tube heat exchanger found in conventional baseboards. The same heat output of traditional baseboard heat distribution systems operating at higher water supply temperatures (71.1 – 82.2 °C) can also be achieved at lower temperatures (≤60 °C). Specifically, results indicate that the technology can produce more than a 46.7% improvement in the heat transfer output at temperatures as low as 60 °C (140 °F), effectively matching the same output range achieved by 71.1 – 82.2 °C (160–180 °F) water supply temperatures. An important benefit of this solution is that it utilizes the existing infrastructure as opposed to requiring the replacement of the entire distribution system. Additionally, this technology enables existing building infrastructure to be coupled with newer, high-efficiency heating systems such as condensing boilers, solar-thermal systems, and geothermal/air-to-water heat pumps that may produce lower water supply temperatures (60 °C). A geospatially resolved techno-economic and environmental analysis is completed and presented to further understand the equivalent carbon footprint of enabling higher efficiency heat generation systems with the improved efficiency heat distribution system disclosed. Using 2021 grid-average emission factors, an emission reduction of up to a 67.5% decrease (2658 kgCO 2 /yr) for a single-family home, depending on state and climate region, could be realized by replacing a traditional natural gas-fired boiler with an air-to-water heat pump coupled to the same high-temperature heat distribution system along with the low-cost retrofit solution. A complete CO 2 emission reduction of 6688 kgCO 2 /yr, depending on state and climate region, could be realized if all electricity is further renewably sourced. Thus, this study provides a possible pathway towards enabling the reduction of operational emissions in space heating.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗