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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 433 records · Page 24
All sourcesNASA NTRSDOE OSTI
NASA NTRS2014

Development Status of a CVD System to Deposit Tungsten onto UO2 Powder via the WCI6 Process

Nuclear Thermal Propulsion (NTP) is under development for deep space exploration. NTP's high specific impulse (> 850 second) enables a large range of destinations, shorter trip durations, and improved reliability. W-60vol%UO2 CERMET fuel development efforts emphasize fabrication, performance testing and process optimization to meet service life requirements. Fuel elements must be able to survive operation in excess of 2850 K, exposure to flowing hydrogen (H2), vibration, acoustic, and radiation conditions. CTE mismatch between W and UO2 result in high thermal stresses and lead to mechanical failure as a result UO2 reduction by hot hydrogen (H2) [1]. Improved powder metallurgy fabrication process control and mitigated fuel loss can be attained by coating UO2 starting powders within a layer of high density tungsten [2]. This paper discusses the advances of a fluidized bed chemical vapor deposition (CVD) system that utilizes the H2-WCl6 reduction process.

Mireles, O. R.↗
NASA NTRS2015

Optimization of a Wcl6 CVD System to Coat UO2 Powder with Tungsten

In order to achieve deep space exploration via Nuclear Thermal Propulsion (NTP), Marshall Space Flight Center (MSFC) is developing W-UO2 CERMET fuel elements, with focus on fabrication, testing, and process optimization. A risk of fuel loss is present due to the CTE mismatch between tungsten and UO2 in the W-60vol%UO2 fuel element, leading to high thermal stresses. This fuel loss can be reduced by coating the spherical UO2 particles with tungsten via H2/WCl6 reduction in a fluidized bed CVD system. Since the latest incarnation of the inverted reactor was completed, various minor modifications to the system design were completed, including an inverted frit sublimer. In order to optimize the parameters to achieve the desired tungsten coating thickness, a number of trials using surrogate HfO2 powder were performed. The furnace temperature was varied between 930 C and 1000degC, and the sublimer temperature was varied between 140 C and 200 C. Each trial lasted 73-82 minutes, with one lasting 205 minutes. A total of 13 trials were performed over the course of three months, two of which were re-coatings of previous trials. The powder samples were weighed before and after coating to roughly determine mass gain, and Scanning Electron Microscope (SEM) data was also obtained. Initial mass results indicated that the rate of layer deposition was lower than desired in all of the trials. SEM confirmed that while a uniform coating was obtained, the average coating thickness was 9.1% of the goal. The two re-coating trials did increase the thickness of the tungsten layer, but only to an average 14.3% of the goal. Therefore, the number of CVD runs required to fully coat one batch of material with the current configuration is not feasible for high production rates. Therefore, the system will be modified to operate with a negative pressure environment. This will allow for better gas mixing and more efficient heating of the substrate material, yielding greater tungsten coating per trial.

Belancik, Grace A.↗
NASA NTRS2015

Nanoelectric Materials Laboratory Development

The Ultracapacitor Research and Development project is a collaborative effort between the NASA Marshall Space Flight Center's (MSFC's) ES43 Parts, Packaging, and Fabrication Branch and the EM41 Nonmetallic Materials Branch. NASA's Ultracapacitor Research is an effort to develop solid-state energy storage devices through processing of ceramic materials into printable dielectric inks, which can be formed and treated to produce solid state ultracapacitor cells capable of exceeding lithium-ion battery energy density at a fraction of the weight. Research and development efforts into solid state ultracapacitors have highlighted a series of technical challenges such as understanding as-received nature of ceramic powders, treatment and optimization of ceramic powders, dielectric and conductor ink formulation, and firing of printed (green) ultracapacitor cells. Two facilities have been continually developed since project inception: the Additive Electronics Lab in Bldg. 4487 and the Nanoelectric Materials Lab in Bldg. 4602. The Nanoelectric Materials Lab has become a unique facility at MSFC, capable of custom processing a wide range of media for additive electronics. As research has progressed, it was discovered that additional in-house processing was necessary to achieve smaller, more uniform particle diameters. A vibratory mill was obtained that can agitate powder and media in three directions, which has shown to be much more effective than ball milling. However, in order to understand the effects of milling, a particle size analysis system has been installed to characterize as-received and milled materials Continued research into the ultracapacitor technology included advanced milling and optimization of ceramic nanoparticles, fluidized bed treatment of atomic-layer deposition- (ALD-) coated ceramic particles, custom development of dielectric and conductor inks, as well as custom ink precursors such as polyvinylidene diflouride- (PVDF-) loaded vehicles. Experiments with graphene-based inks were also conducted.

Allen, Lee↗
NASA NTRS2018

Current Activities in the Advanced Exploration Systems ISRU Project

Media Filter MOXIE support: completed flow performance tests and initial dust loading tests of the MOXIE HEPA filter in the Mars Flow Loop Designed and fabricated prototype full-scale scroll filter for testing of renewable filter performance Mars Flow Loop upgrades: installed more sensitive instrumentation, improved imaging, and increased run duration capability Electrostatic Precipitator (ESP) Plasma-physics based model predicts particle charge and trajectory Characterizing dust environment from fluidized-bed injection dust environment using laser sheet visualization and Fine Particle Analyzer Sabatier Design Study Defined the Sabatier design space, including reactor type, thermal management, gas recycling/separation Modeled Sabatier systems with one or two reactors with different types of thermal management Adding thermal management schemes and recycling and gas separation to model Catalyst Screening Performing compression testing on new and used catalyst pellets Performing vibration testing on different catalyst pellet types under different load conditions Preparing to test catalysts for performance and degradation

In-Situ Resource Utilization↗
DOE OSTI2020

Transformation enabled nitride magnets absent rare earths and a process of making the same

A process for producing an ordered martensitic iron nitride powder that is suitable for use as a permanent magnetic material is provided. The process includes fabricating an iron alloy powder having a desired composition and uniformity; nitriding the iron alloy powder by contacting the material with a nitrogen source in a fluidized bed reactor to produce a nitride iron powder; transforming the nitride iron powder to a disordered martensitic phase; annealing the disordered martensitic phase to an ordered martensitic phase; and separating the ordered martensitic phase from the iron nitride powder to yield an ordered martensitic iron nitride powder.

Matthiesen, David↗
DOE OSTI2021

An Orthogonal Recursive Bisection (ORB) Based Time Advancement Algorithm for CFD-DEM Solvers

The time integration of the granular phase in coupled computational fluid dynamics (CFD) – discrete element method (DEM) simulations presents a unique computational challenge brought about by the large variations in particle collisional time scales. Particles in the dilute regions of the computational domain can be advanced with large time steps while dense regions require much smaller time increments. However, the time step size in most solvers is globally set as the limit for accuracy and stability imposed by the collisions and is typically orders of magnitude less than that required away from collisions. This work addresses this precise issue and provides a strategy to avoid the use of a global conservative small time step size for the entire set of particles.A novel time stepping algorithm for CFD-DEM solvers using a partitioning approach using orthogonal recursive bisection (ORB) that allows for variable time steps among particles is described and its computational performance is compared against baseline explicit methods, typically used in several CFD-DEM solvers. ORB has advantages of being relatively quick and easy to update incrementally and has the required heuristic behavior (i.e., it will split the region in half with a cluster on each side) when groups of particles are well separated (clustered). The algorithm presented in this work uses a local time stepping approach to resolve collisional time scales for subsets of particles that are present at the leaves of the ORB, thereby resulting in substantial reduction of computational cost. The parallel implementation of this method where a ``knapsack” algorithm is used in tandem with ORB for effective load-balancing is also presented, where a best possible partitioning is obtained based on number of particles and local time-stepping costs. The algorithm is tested against benchmark problems with varying particle distributions that include fluidized bed and riser flow scenarios. Preliminary results indicate that the approach is 2-3X faster than traditional explicit methods for problems that involve both dense and dilute regions, while maintaining the same level of accuracy.

adaptive timestepping↗
DOE OSTI2022

Systems and methods for producing fuel intermediates

The present disclosure relates to a method that includes pyrolyzing a biomass to produce a pyrolysis oil and upgrading the pyrolysis oil to yield a first upgraded pyrolysis oil, where the pyrolysis oil is in at least one of a liquid phase and/or a vapor phase, the pyrolyzing is performed in a pyrolysis reactor at a first temperature between 400° C. and 600° C., the biomass has a residence time of less than five seconds in the pyrolysis reactor, the upgrading is performed in a fluidized bed reactor, and the upgrading is catalyzed using a zeolite.

09 BIOMASS FUELS↗
DOE OSTI2023

Advanced Analytical Methodologies Enable Feedstock Screening and Correlation to Pyrolysis Yields and Catalytic Upgrading

Pyrolysis of lignocellulosic biomass can serve as a powerful pathway for the generation of renewable fuels and industrial products. However, procurement of some biomass may be costly, especially when there is competition for alternative uses. Forestry and agricultural byproducts may serve as valuable pyrolysis feedstocks due to their high availability and low cost. Although waste products may fill demand for affordable pyrolysis feedstocks, they are often high in ash and extractives which contribute to unfavorable changes in pyrolysis vapor composition, as well as end products. The work presented here investigates the correlations between various pine anatomical fractions to understand their effect on pyrolysis oil composition for forest residues. Analytical pyrolysis coupled to direct analysis by molecular beam mass spectrometry (MBMS) provides real-time monitoring of pyrolysis vapor composition, even for compounds that are not amenable to gas chromatography. Statistical analysis of MBMS data from the fast pyrolysis (FP) of clean pine, cambium, twigs and branches, needles, bark, and a forest residue samples revealed that bark and needles made the greatest differences in the vapor composition of forest residues during pyrolysis and were enriched in resin acids, furfural derivatives, and ions that have been previously observed from catalysis corresponding to ash content. These results were also compared to catalytic fast pyrolysis (CFP) using a platinum on titania catalyst, and correlations between FP and CFP products were observed for the anatomical fractions. The forest residues and corresponding anatomical fractions from a stand of 23-year-old pine will be converted by fast pyrolysis in a bench-scale 2-inch fluidized-bed reactor, and statistical correlations between the bench-scale products and analytical-scale pyrolysis vapors will be shown. This work highlights the power of advanced analytical methodologies in determining the contributions of vapor components to catalytic pyrolysis outcomes for mixed feedstocks and demonstrates the use of analytical methodologies to better screen feedstocks prior to pyrolysis.

analytical↗
DOE OSTI2023

Maintaining Microstructure – The Path to Successful Technology Maturation in Fluidized Systems

Scaling circulating fluidized bed risers has been a point of contention for nearly a century. There have been numerous attempts to define various methodologies. These have all fallen short of providing a robust approach, primarily due to a lack of maintaining microstructure dynamics – a key factor in maintain interphase heat and mass transfer. Recent work by the author put forward an approach based up maintaining dynamic similarity at different scales by ensuring that the microstructure remained similar by maintaining statistical and chaotic parameters across the scale. That work relied on a dimensionless regime map in which the x-axis was defined by the ratio of the solids flux to the saturation carrying capacity. This latter property was only good within the range of the data and it became evident that extrapolation beyond the limits of the data could induce unrealistic conditions. Therefore, literature was reviewed to develop a better correlation for the saturation carrying capacity. In doing so, a critical diameter concept was developed and applied to the correlations for both Geldart Group A and B materials. The critical diameter for Geldart Group A and B materials is 0.2 m and 0.3 m, respectively. The paper then gives examples on how to use the scaling approach to maintain dynamic similarity across the scales.<br>

Breault, Ronald↗
DOE OSTI2023

Catalytic Upgrading of Pyrolysis Products for the Production of Sustainable Aviation Fuel

The objective of this project is advance the state-of-technology for a catalytic fast pyrolysis (CFP) + hydrotreating (HT) process to produce sustainable aviation fuel and other biogenic products. Our approach focuses on performing integrated experiments using realistic biomass feedstocks and non-noble metal technical catalyst formulations. CFP is performed in an ex-situ configuration using a fluidized bed reactor without co-fed hydrogen. Research advancements over the past two years include establishing benchmark yield structures and compositional data for each step of the biomass-to-SAF process, demonstrating the ability to produce a cycloalkane-rich SAF product that meets key ASTM 4054 guidelines, generating benchmark characterization data for technical catalyst formulations with an emphasis on determining the unique composition and combustion properties of biogenic coke, and establishing bio-oil critical material attributes to mitigate the risk of plugging during down-stream hydroprocessing. Other impacts from this project include generation of broadly enabling scientific knowledge (12 publications/12 presentations since 2021), engagement with industry partners (Johnson Matthey, ExxonMobil, Phillips 66), and identification of a promising pathway to market that addresses emerging demands for biogenic refinery feedstocks.

biomass↗
DOE OSTI2023

Flexible Gasification of Coal and Biomass to Generate Carbon Free Electric Power and Hydrogen

This paper describes the development of a coal and biomass-fed plant concept to co-produce electric power and hydrogen with net-negative CO2 emissions under the aegis of the 21st Century Power Plant initiative of the U.S. Department of Energy (DOE), whose goal is to advance innovative power plant concepts that are capable of flexible, net-zero carbon emission operations while producing cost-effective “blue” hydrogen to support economy-wide decarbonization goals. The proposed standalone plant will be in Nebraska, USA. The specified design feedstock is a hybrid blend of Powder River Basin (PRB) subbituminous coal from Wyoming and local Nebraska biomass (corn stover), 50 wt.% each (dry basis). Other potential feedstocks, including woody biomass (eastern red cedar) and waste plastic (auto shredder residue) were evaluated or reviewed as alternates. The proposed process block comprises a high-pressure, oxygen-blown fluidized bed gasifier (GTI Energy U-GAS® process) coupled with water gas shift, the Selexol process for acid gas (H2S and CO2) removal, and pressure-swing adsorption (PSA) to yield 8,500 kg/h of high-purity hydrogen. The off gas from the PSA unit is used in the power block (gas turbine combined cycle) to generate electric power to support the gasification process, hydrogen production, and 50 MWe net electric power to the grid. All major plant equipment including the gasifier, gas cleanup system, and power generation are commercially available and proven in other applications and considered at TRL 8-9. However, gasification of corn stover biomass is considered at TRL 6. Overall thermal efficiency of the plant is 50% (net HHV) with net atmospheric CO2 removal at a rate of 250-300,000 tpa. Design activities necessary to provide input to a FEED study (Phase II of the project), including the development of the Environmental Information Volume (EIV) for the host site, and an investment case, based on a pro-forma pre-FEED level cost estimate, have been completed and are described in detail in this paper.

Gülen, S. Can↗
NASA NTRS2013

Advanced Magnetic Materials Methods and Numerical Models for Fluidization in Microgravity and Hypogravity

To support long-duration manned missions in space such as a permanent lunar base, Mars transit, or Mars Surface Mission, improved methods for the treatment of solid wastes, particularly methods that recover valuable resources, are needed. The ability to operate under microgravity and hypogravity conditions is essential to meet this objective. The utilization of magnetic forces to manipulate granular magnetic media has provided the means to treat solid wastes under variable gravity conditions by filtration using a consolidated magnetic media bed followed by thermal processing of the solid wastes in a fluidized bed reactor. Non-uniform magnetic fields will produce a magnetic field gradient in a bed of magnetically susceptible media toward the distributor plate of a fluidized bed reactor. A correctly oriented magnetic field gradient will generate a downward direct force on magnetic media that can substitute for gravitational force in microgravity, or which may augment low levels of gravity, such as on the Moon or Mars. This approach is termed Gradient Magnetically Assisted Fluidization (G-MAFB), in which the magnitude of the force on the fluidized media depends upon the intensity of the magnetic field (H), the intensity of the field gradient (dH/dz), and the magnetic susceptibility of the media. Fluidized beds based on the G-MAFB process can operate in any gravitational environment by tuning the magnetic field appropriately. Magnetic materials and methods have been developed that enable G-MAFB operation under variable gravity conditions.

Atwater, James↗
DOE OSTI2020

Fluidization of Group A Glass Particles: Experiments and Preliminary Validation

This work is aimed at providing reliable high-quality data from fluidization experiments. Geldart Group A glass beads are used as bed material. The fluidizing medium is air at atmospheric pressure which enters the system at 40% relative humidity. The air inlet velocity is varied over a broad range from 2 U mf to 26 U mf , where the minimum fluidization velocity, U mf , is 0.608 cm/s. There is not a significant change in the mean values of differential pressure; however, there are noticeable trends in their standard deviation values. Preliminary validation studies are performed using the open-source software Multiphase Flow with Interphase eXchanges (MFiX) developed by the National Energy Technology Laboratory (NETL). The results from Eulerian-Eulerian (MFiX-TFM, two-fluid model) and Eulerian-Lagrangian (MFiX-PIC, particle-in-cell) formulations are compared. The work presented in this report highlights the applicability of MFiX-PIC for large-scale applications, and reveals that PIC simulation offers a suitable alternative to TFM simulation when effects due to multiple components or polydispersity are significant. PIC modeling provides a readily extendible framework for such systems. However, PIC models do rely on an empirical closure for inter-particle stress. Some solution discrepancies were evident in MFiX-PIC predictions which require further analysis. As such, the study underlines the need for a systematic approach to quantify the sources of numerical uncertainty within the PIC model. However, even with known empiricism, MFiX-PIC has demonstrated considerable potential in analyzing gas-solid systems. The results obtained are encouraging and warrant further investigation to improve the predictive capability of MFiX-PIC.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Micromechanical origin of heat transfer to granular flow

Heat transfer across a granular flow is comprised of two resistances in series : near the wall and within the bulk particle bed, neither of which is well understood due to the lack of experimental probes to separate their respective contribution. Here, we use a frequency modulated photothermal technique to separately quantify the thermal resistances in the near-wall and the bulk bed regions of particles in flowing states. Compared to the stationary state, the flowing leads to a higher near-wall resistance and a lower thermal conductivity of bulk beds. As a result, coupled with discrete element method simulation, we show that the near-wall resistance can be explained by particle diffusion in granular flows.

14 SOLAR ENERGY↗
DOE OSTI2024

A Study of the Transition to Turbulence in a Bed of 67 Spherical Pebbles

Packed beds are commonly found in many engineering systems and have been widely studied for decades. A relatively new packed bed system is the Pebble Bed Reactor, a type of generation-IV nuclear reactor. Unlike many of the packed beds encountered in chemical and process engineering applications, Pebble Bed Reactors are larger and operate at significantly higher Reynolds numbers. As a result of these differences, there is a very limited amount of information on the detailed flow physics that exist in these complex geometries. This work seeks to contribute to a growing database of flow data for Pebble Bed Reactor systems by performing Direct Numerical Simulations of the flow in an experimental bed of 67 pebbles for a range of conditions. Simulations are performed at a Prandtl number of 0.66 and Reynolds numbers from 300–600. These Reynolds numbers are chosen to gain additional knowledge on the spatial development of turbulence in these systems. Analysis of the Turbulent Kinetic Energy, turbulence anisotropy, and Turbulent Heat Flux is performed. Results demonstrate significant development of the TKE across the tested range of Reynolds numbers. Examination of both the TKE and THF reveal that development first occurs near the center of the bed and propagates radially as the flow moves further into the bed. Notable regions of negative production of turbulent kinetic energy are observed in regions where flow accelerates around pebble contact points. Furthermore, these regions are found to coincide with regions of 1-component turbulence.Kindly check and confirm, all authors email id is correctly identified.These are correct

Direct numberical simulation↗
DOE OSTI2022

At-Line Sampling and Characterization of Pyrolytic Vapors from Biomass Feedstock Blends Using SPME-GC/MS-PCA: Influence of Char on Fast Pyrolysis

Solid-phase microextraction (SPME) coupled with GC-MS analysis was used for at-line sampling of pyrolytic vapors produced during fast pyrolysis of biomass. The pure and binary blends of switchgrass (SWG) and pine harvest residues (PT6) were used as feedstock. Sequential SPME sampling allowed for monitoring of changes in the pyrolysis vapors as char accumulated in the fluid bed. The concentration and composition of the vapors desorbed from the SPME fibers were investigated using GC-MS, and the data sets were then analyzed using principal component analysis (PCA) to compare the composition of the pyrolysis vapors over the course of the pyrolysis run. The chemical composition of both carbohydrate and lignin fragments varied as the char builds up in the reactor bed. Fragments derived from cellulose and xylan included anhydrosugars, furans and light oxygenated compounds. Lignin fragments included methoxyphenols, phenolic ketones and aldehydes, low molecular weight aromatics. The composition of the carbohydrate fragments changed more than the lignin fragments as the char build-up in the fluid bed. This combination of SPME-GC/MS-PCA were a novel, easy and effective method for measuring the composition and changes in the composition of pyrolysis vapors during the fast pyrolysis process. Here, this work also highlighted the effect of char build-up on the composition of the overall pyrolysis vapors.

09 BIOMASS FUELS↗