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At least 433 records · Page 24

Modifications to Solar Titan-130 Combustion Systems for Efficient, High Turndown Operation

The project team of Southwest Research Institute® (SwRI®), Solar Turbines Incorporated (Solar), the Electric Power Research Institute (EPRI), the University of California, Irvine (UCI), and the Georgia Institute of Technology (Georgia Tech) investigated methods to allow higher efficiency part-load operation of a Solar Titan 130 gas turbine. The objective was to develop a low-emission combustion system capable of sustaining combustion and avoiding lean blowout during high turndown operation, which would allow the gas turbine to operate as efficiently as possible at part load. Currently, electric utility markets are beginning to experience substantial increases in renewable energy generation. Some of these renewable energy sources have highly variable output in an uncontrolled manner. In order to maintain grid stability, there is a need for power plants to ramp up power to the grid rapidly to make up for drops in renewable generation. This is often termed spinning reserve, but the size of this reserve may need to increase as renewable penetration into the electric utility market increases. Small combined heat and power (CHP) power plants provide a promising option for meeting this spinning reserve requirement. In order to operate in spinning reserve while still meeting the heat requirements for the CHP, the gas turbine needs to operate efficiently at very low loads. Efficient, high turndown operations in this engine are limited by the lean flammability limit of the premixed combustion system. This project sought enhance the lean operability range of the Titan 130 combustor. First, the project team participated in a brainstorming activity and ultimately selected two concepts to explore: fuel augmentation with hydrogen (H2) to improve the stability at lean operating conditions and modifications to the fuel nozzle to improve the emissions performance at lean operating conditions. Analytical and laboratory investigations were accomplished by UCI to investigate the efficacy of H2 addition at improving lean blow out (LBO) limits and the resulting emissions. These investigations used a variety of chemical reactor network (CRN) and CFD models, validated against laboratory data, to model the impact of H 2 and inform the experimental efforts accomplished by SwRI and Solar. Ultimately, both the CRN and CFD models yielded generally good agreement with the experimental data below a particular temperature threshold. Atmospheric tests of a full-scale T130 annular combustor were performed at SwRI facilities in San Antonio, Texas, to investigate the use of H 2 addition. For these tests, the T130 combustion system remained largely unchanged; minor modifications were performed to the fuel ducting to allow for the safe use of H 2 . The test ultimately demonstrated that the addition of H 2 to the fuel mixture significantly increased the AFR ratio at which the combustor could operate. This improvement to the LBO limit should allow for less use of compressor bleed and less throttling needed by the inlet guide vanes (IGV). This in turn could result in more efficient operation of the gas turbine at lower load points. The second modification explored in this work was a direct modification to the T130 injector. The project team hypothesized that modifications to the pilot of the T130 injector could provide lower emissions at high turn-down operations. These modifications were manufactured and explored by the team at Solar. High pressure rig tests, originally slated to occur at SwRI, were ultimately accomplished by Solar to maintain overall project budget and mitigate cost growth attributable to supply chain issues and inflation. The pressurized rig tests ultimately showed that the SwRI Project No. 18.24153 - DE-EE0008415 Page 2 Final Technical Report January 24, 2024 modifications did not significantly alter the performance of the combustion system at the high turn-down conditions; both the modified injectors and the baseline configuration exhibited elevated emissions comparted to the full-load operating condition. A final set of studies performed by EPRI investigated the benefit-cost of flexible CHP as well as a grid interconnection study for the California Independent System Operator (CAISO) grid. These studies considered: traditional CHP with no spinning reserve available for on-demand grid support, 50% flexible CHP where 50% of the machine’s capacity is consumed by on-site baseload operations while providing an additional 50% capacity for on-demand grid support, and 70% flexible CHP where 70% of capacity is consumed on-site by baseload operations and 30% is available for on-demand grid support. In all cases, the analyses showed a benefit-to-cost ratio greater than unity implying a positive net present value for all configurations. However, the traditional CHP showed the most economic benefit. These results are sensitive to several factors, many of which are not fully known and may vary over time. Thus site owners must be convinced that taking up the increased costs and risks from flexible CHP would be worth implementing. As the grid in California and across the country transition to incorporate larger renewable energy generation, flexible CHP can provide much needed operating reserves and dispatchability. Alternative fuel options, such as hydrogen blending and biofuels, may also lower carbon intensities of CHP. Flexible CHP should be examined in the evolving market to understand innovative business models, changes market rules and services, and new technologies.

20 FOSSIL-FUELED POWER PLANTS↗

Connected and Learning Based Optimal Freight Management for Efficiency

The management of the future heterogenous fleet is a complex decision-making problem. The heterogenous fleet is emerging as decarbonization technologies are deployed by fleets toward lowering the freight operation emissions in Medium and Heavy-duty vehicles. Traditionally, in fleets characterized by a homogeneous Diesel Internal Combustion Engine (ICE) powertrain, the process of fleet planning and operational optimization unfolds sequentially without the necessity to account for powertrain and vehicle-specific characteristics during dispatch decisions. Fleets with trucks less than 5 years old tend to maintain stable vehicle efficiency with minimal operational reliability risks for fleet managers. However, the landscape changes with the incorporation of emerging powertrain technologies, which lack extensive operational data and service experiences. This includes technologies like hybrid, Electric, Fuel Cell, or alternative fuel ICE. Operational decisions for fleets featuring heterogeneous powertrain technologies and facing limited access to alternative fueling and charging stations become intricate, requiring careful consideration and optimization at each dispatch. The difference in efficiency characteristics of emerging technologies, their range limitations, and the restricted availability of charging/alternative fueling infrastructure, coupled with sensitivity to driving conditions (e.g., EV range reduction in low temperatures) and their impact on component aging (such as batteries), become pivotal factors influencing the reliable and efficient freight transportation. To make the path toward low emission freight transportation efficient and reliable, an AI-assisted fleet management software is developed in this project to help fleet managers in optimizing both adoption of emerging powertrain decarbonization, connected and automated technologies and also operating the fleet after such technologies are deployed as schematically. Freight transportation requirements are different depending on the cargos to be shipped, customer requirements and regions of operations. This further highlights the need for software and digital solutions to tailor deployment and operation of emerging powertrain, connectivity, and automation technologies toward the specific fleet operation requirements. The fleet management optimizer was also integrated with a model of the fleet to simulate the operation of the fleet over 1 year of the baseline fleet operation (250,000+ shipments) indicating the significance of day-to-day variations on emissions and energy consumption of a freight transportation fleet. The results demonstrate ≥20% improvement in freight efficiency in terms of WTW CO2 per ton-mile of cargo shipments while all fleet operation constraints are enforced, and the cost (CapEx and OpEx) is minimized.

33 ADVANCED PROPULSION SYSTEMS↗

Computational Analysis of Hydraulic Efficiency of Michigan DOT Cover C

Drainage structures are used to capture stormwater runoff in streets and highways in urban environments. These drainage structures, which typically consist of catch basins with grates, inlets, or combination grates/inlets, collect stormwater runoff and discharge through buried conveyance systems. They are strategically placed for public safety in curb and gutter systems to provide efficient drainage of water from roadways and thus reduce the risk of hydroplaning. The performance of drainage structures is measured in terms of hydraulic efficiency, which is defined as the percentage of flow captured by the basin as compared to the total flow drainage to the structure. Understanding of the performance of these drainage structures helps designers properly space inlets to promote an economic design that ensures the safety of the traveling public. The current design methodology used to determine drainage structure follows guidelines established in the current Michigan Department of Transportation (MDOT) Drainage Manual (2006). The guidelines in the MDOT Drainage Manual were modeled after the Federal Highway Administration’s (FHWA) Hydraulic Engineering Circular 22 “Urban Drainage Design” (HEC-22). HEC-22 includes empirically derived equations to calculate the interception capacity of drainage structures for several commonly used grate configurations, such as the parallel bar, curved vane and tilt bar grates, which are based on a research study performed by Burgi et al. in the 1970s. MDOT uses several drainage structures to capture runoff that are detailed as Standard Plans. Many of these drainage structures utilize sinusoidal type grates that are not described in HEC-22. Physical modeling of these structures has been limited, posing the need to have them analyzed to verify their capture efficiency. Current MDOT practice is to assume a similar sized reticuline grate, as described in HEC-22, for capture efficiencies. Until recently, evaluating the hydraulic performance of drainage structures was limited to physical modeling in a hydraulics laboratory. With advances in engineering software and computing power, computational fluid dynamics (CFD) modeling has become a more cost-effective alternative. The Federal Highway Administration (FHWA) provides states the option to evaluate their drainage structures using CFD through the Transportation Pooled Fund Program. This study, “Computational Analysis of Hydraulic Efficiency of Michigan DOT Cover C,” was carried out using the pooled fund. MDOT’s Cover C was chosen as the first test candidate, given its similar sinusoidal pattern to other MDOT grates, but it is typically used for high-volume, higher speed applications. A similar version, Cover CX, is used on interstate highways but does not have traverse bars for bicycle safety. Additional grates may be considered for evaluation in the future.

42 ENGINEERING↗

Microwave Absorbing Perovskite Catalysts for Efficient Electrification of Syngas Production from CO2 and Methane

Microwave absorbing catalysts have the potential to make thermal reactions such as methane reforming (CH4 + CO2 + H2O → H2 + CO) into carbon negative processes when coupled with decarbonized electricity. Due to microwaves directly heating the catalyst rather than heating the reactor and gases, even high temperature reactions such as dry reforming methane (DRM, CH4 + CO2 → H2 + CO) can be achieved rapidly, efficiently, and on-demand, ideal for coupling with intermittent renewable electricity. However, microwave catalysts present unique design challenges due to the same material needing to both efficiently absorb microwaves in oxidative and reductive reaction conditions and be an efficient and stable catalyst in inherently non-isothermal reactors. We screened from over 28 catalysts in the La0.8Sr0.2(Co-Ni-Mn)O3 perovskite solid-solution family to determine promising microwave reforming catalysts and identify design principles for effective materials. The best performing catalyst candidate was able to produce syngas ratios (H2:CO) from 1-3, and scale up testing showed CO and H2 production efficiencies rivaling conventional carbon intensive steam reforming efficiencies at the liters per minute level of production.

Marin, Christopher↗

Consumer Benefits of Clean Energy: Energy Efficiency

Meeting national and state decarbonization goals requires a transition to clean energy technologies. Energy efficiency, demand flexibility, renewable energy and storage can reduce consumers’ electricity bills, lower total electricity system costs, and provide health and resilience benefits. Berkeley Lab developed a series of briefs that explore these consumer benefits of a clean energy transition. This brief focuses on energy efficiency benefits, and builds on prior analysis from Berkeley Lab’s Cost of Saved Energy database. We show that energy efficiency remains a low-cost energy and capacity resource; the levelized cost of saving energy for the programs included in the analysis is $\$0.02$/kilowatt-hour and the cost of saving peak demand is less $\$120$/kilowatt. Understanding the impact of the program mix, portfolio size, and duration of implementation for customer-funded energy efficiency portfolios can guide regulatory oversight of these programs, help utilities better utilize energy efficiency as a resource, and inform building energy decarbonization policies.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Development of advanced combustion strategies for direct injection heavy duty LPG engines to achieve near-diesel engine efficiency

The Vehicle Technologies Office funds early-stage, high-risk research to develop technology upon which industry can implement innovative transportation energy technologies that increase efficiency, decrease cost, and expand use of domestic energy sources, such as liquefied petroleum gas (LPG). To improve the viability of medium and heavy-duty vehicles the LPG engine efficiency must be closer to that of diesel. This work addresses fundamental limitations to achieve diesel-like efficiencies in heavy duty on-road LPG engines. The primary goal of this research is to achieve diesel-like efficiencies in heavy duty on-road LPG engines, focusing on the Cummins 15-liter engine platform (baseline diesel efficiency of 44% at peak torque). That goal has been achieved, though more work is needed to facilitate practical implementation of the developed technologies.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Highly Efficient Regeneration Module for Carbon Capture Systems in NGCC Applications

The objective of this project is to design, fabricate, and test a highly efficient regeneration module capable of providing an ultra-lean absorption solution that is required for capturing CO 2 from dilute sources at 95% or better efficiency. By integrating this advanced regenerator module with SRI International’s Mixed Salt Process (MSP) absorption modules, SRI expects to demonstrate significant progress toward a reduction in cost of capture versus the DOE reference natural gas combined cycle (NGCC) plant with carbon capture. SRI designed, built, and tested an advanced stripper to enhance the performance of SRI’s MSP for CO 2 capture – a transformational ammonia-based solvent technology – for natural gas (NG) power sources. The testing of the advanced stripper for MSP was conducted at an SRI site using a simulated flue gas stream equivalent to about 10 kWe. The research work included modeling of the advanced stripper and integrating it with the MSP absorbers; studying the strategies for producing very highly alkaline lean solvent with minimized emissions; operating the stripper with advanced heat integration to improve process efficiencies; and collecting critically important data for a detailed techno-economic analysis (TEA). The project tasks were designed to address concerns relating to scale-up and integration of the technology to NG power plants—more specifically, to maximize the carbon capture efficiency achievable with MSP and identify pathways to achieve higher capture efficiencies and ultimately zero net carbon emissions. SRI teamed up with a process modeling company (OLI Systems), a process and chemical engineering company (Trimeric Corporation), and a cost-sharing commercial partner (Baker-Hughes – a leading multinational company that designs, manufactures, and services transformative energy technologies) to execute the project. The research findings will accelerate the MSP development and pave the way for the technology to reach the DOE’s goal, and ultimately commercialization of the MSP technology for low-cost CO 2 capture from NGCC flue gas and other dilute CO 2 sources.

03 NATURAL GAS↗

Reimagining Energy Efficiency Resource Standards

Energy Efficiency Resource Standards (EERS) are a long-standing policy used to advance state goals and priorities, such as reliability, affordability and decarbonization. They ensure cost-effective energy efficiency is used to lower energy consumption, reduce peak demand, and enable grid flexibility. Adapting EERS through strategic design, and integrating EERS into broader energy plans and policies, can help states optimize their approach to meet modern and evolving power system needs and achieve sustainable energy outcomes. This report examines how states consider energy efficiency in the context of four policy priorities: providing grid benefits, addressing load growth, reducing emissions, and promoting affordability. It provides examples of states that are pursuing these priorities, reviews the role of energy efficiency in them and identifies opportunities to further promote energy efficiency alongside the priorities. Decisionmakers and stakeholders can draw directly from these examples and findings to design an EERS that maximizes co-benefits, captures synergies, and promotes consideration of the all the possible solutions to advance their goals.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Towards High-Efficiency Particle Detection Using Superconducting Microwire Arrays

We present a detailed study of an 8-channel $1\times1$~mm$^{2}$ WSi superconducting microwire single photon detector (SMSPD) array exposed to 120~GeV hadron beam and 120~GeV muon beam at the CERN Super Proton Synchrotron H6 beamline. Following up on our first detailed characterization of the efficiency and response of an SMSPD fabricated on a 3~nm WSi film, we report measurements of enhanced particle detection efficiency using a sensor fabricated from a thicker 4.7~nm-thick WSi film. We also report the first SMSPD detection efficiency measurement made for muons. Measurements are enabled by a silicon tracking telescope providing 10~$\mu$m in situ spatial resolution. The results show a detection efficiency of 75\% and a time resolution of about 130~ps across pixels. These findings represent a significant advancement toward developing high-efficiency SMSPD charged particle tracking systems with simultaneous precision timing, with potential applications in future accelerator-based experiments such as the FCC-ee and Muon Collider.

Wang, Christina [Fermilab]↗

Tau-Jet Matching and Tag-and-Probe Tau Tagging Efficiencies for HH→bbτ+τ− Searches Using Run 3 CMS Scouting Data

We are studying tau-jet matching efficiency and tau tagging efficiency for the search for Higgs boson pair production in the HH→bbτ+τ− decay channel using Run 3 CMS scouting data. Collision events in the CMS detector produce many particle candidates, so jets are clustered using the anti-kT algorithm to identify possible tau signatures. In Monte Carlo simulation, tau-jet matching efficiency can be measured by comparing generated taus to reconstructed jets. In actual collision data, however, generated taus are not available, so we use a tag-and-probe method with Z→τ+τ− candidate events. In this method, one tau candidate is used as the tag and the other as the probe. The invariant mass of the tau-pair candidates is plotted and fitted with signal and background functions to estimate the number of real tau events and determine the tagging efficiency. By comparing efficiencies in data and Monte Carlo simulation, this work helps evaluate the performance of scouting-based tau reconstruction and tau tagging for future HH→bbτ+τ− searches.

Bellot, Annella [North Central Coll.; Fermilab]↗

Tau-Jet Matching and Tag-and-Probe Tau Tagging Efficiencies for HH→bbτ+τ− Searches Using Run 3 CMS Scouting Data

We are studying tau-jet matching efficiency and tau tagging efficiency for the search for Higgs boson pair production in the HH→bbτ+τ− decay channel using Run 3 CMS scouting data. Collision events in the CMS detector produce many particle candidates, so jets are clustered using the anti-kT algorithm to identify possible tau signatures. In Monte Carlo simulation, tau-jet matching efficiency can be measured by comparing generated taus to reconstructed jets. In actual collision data, however, generated taus are not available, so we use a tag-and-probe method with Z→τ+τ− candidate events. In this method, one tau candidate is used as the tag and the other as the probe. The invariant mass of the tau-pair candidates is plotted and fitted with signal and background functions to estimate the number of real tau events and determine the tagging efficiency. By comparing efficiencies in data and Monte Carlo simulation, this work helps evaluate the performance of scouting-based tau reconstruction and tau tagging for future HH→bbτ+τ− searches.

Bellot, Annella [North Central Coll.; Fermilab]↗

Efficient Hydrogen Delivery for Microbial Electrosynthesis via 3D-Printed Cathodes

The efficient delivery of electrochemically in situ produced H 2 can be a key advantage of microbial electrosynthesis over traditional gas fermentation. However, the technical details of how to supply large amounts of electric current per volume in a biocompatible manner remain unresolved. Here, we explored for the first time the flexibility of complex 3D-printed custom electrodes to fine tune H 2 delivery during microbial electrosynthesis. Using a model system for H 2 -mediated electromethanogenesis comprised of 3D fabricated carbon aerogel cathodes plated with nickel-molybdenum and Methanococcus maripaludis, we showed that novel 3D-printed cathodes facilitated sustained and efficient electromethanogenesis from electricity and CO 2 at an unprecedented volumetric production rate of 2.2 L CH4 /L catholyte /day and at a coulombic efficiency of 99%. Importantly, our experiments revealed that the efficiency of this process strongly depends on the current density. At identical total current supplied, larger surface area cathodes enabled higher methane production and minimized escape of H 2 . Specifically, low current density (<1 mA/cm 2 ) enabled by high surface area cathodes was found to be critical for fast start-up times of the microbial culture, stable steady state performance, and high coulombic efficiencies. Our data demonstrate that 3D-printing of electrodes presents a promising design tool to mitigate effects of bubble formation and local pH gradients within the boundary layer and, thus, resolve key critical limitations for in situ electron delivery in microbial electrosynthesis.

03 NATURAL GAS↗

Achieving Diesel-Like Efficiency in a High Stroke-to-Bore Ratio DISI Engine under Stoichiometric Operation

This work explores pathways to achieve diesel-like, high-efficiency combustion with stoichiometric 3-way catalyst compatible spark ignition (SI). A high stroke-to-bore engine design (1.5:1) with cooled exhaust gas recirculation (EGR) and high compression ratio (r c ) was used to improve engine efficiency by up to 30% compared with a production turbocharged gasoline direct injection spark ignition engine. To achieve efficiency improvements, engine experiments were coupled with computational fluid dynamics simulations to guide and explain experimental trends between the original engine and the high stroke-to-bore ratio design (1.5:1). The effects of EGR and late intake valve closing (IVC) and fuel characteristics are investigated through their effects on knock mitigation. Direct injection of 91 RON E10 gasoline, 99 RON E0 gasoline, and liquified petroleum gas (i.e., propane/autogas) were evaluated with geometric rc ranging from 13.3:1 to 16.8:1. Finally, engine experiments demonstrated 47% gross thermal efficiency, and 45% net thermal efficiency at stoichiometric engine operation, at up to 17 bar IMEP and 2000 r/min with 16.8:1 rc.

42 ENGINEERING↗

Leveraging Real-World Driving Data for Design and Impact Evaluation of Energy Efficient Control Strategies

Modeling and simulation are crucial in the development of advanced energy efficient control strategies. Utilizing real-world driving data as the underlying basis for control design and simulation lends veracity to projected real-world energy savings. Standardized drive cycles are limited in their utility for evaluating advanced driving strategies that utilize connectivity and on-vehicle sensing, primarily because they are typically intended for evaluating emissions and fuel economy under controlled conditions. Real-world driving data, because of its scale, is a useful representation of various road types, driving styles, and driving environments. The scale of real-world data also presents challenges in effectively using it in simulations. A fast and efficient simulation methodology is necessary to handle the large number of simulations performed for design analysis and impact evaluation of control strategies. In this study, two methods are presented of leveraging real-world data in both design optimization of energy efficient control strategies and in evaluating the real-world impact of those control strategies upon large-scale deployment. Through these methodologies, strategies with highest impact on energy savings were selected to be implemented as control algorithms. The developed algorithms were incorporated into a vehicle dynamics and powertrain control architecture implemented on a Cadillac CT6 demonstration vehicle. The control algorithms were then exercised on real-world driving scenarios to determine their impact on collective energy savings. The methodology utilizes the large-scale driving data sets maintained by the National Renewable Energy Laboratory to extract real-world driving scenarios and efficient simulation software tools. The insights obtained through this research help in guiding technology selection for energy efficient driving controls.

ARPA-E↗

Data Associated with "Identifying Suitable Front Contacts for High-Efficiency Cd(Se,Te) Solar Cells on Space-Qualified Cover Glass"

This is data associated with the publication " Identifying Suitable Front Contacts for High-Efficiency Cd(Se,Te) Solar Cells on Space-Qualified Cover Glass " by Aesha P. Patel, Ryan Muzzio, Matthew R. Young, Robert Morrissey, Suresh Chaulagain, B. Edward Sartor, Prabodika N. Kaluarachchi, Christian Velez, Joshua A. Brown, Joel N. Duenow, Stephen Glynn, Michael J. Heben, Zhaoning Song, Nikolas J. Podraza, Adam B. Phillips, Randy J. Ellingson, Matthew O. Reese. All data associated with each figure in the manuscript and supplementary should be available in this dataset. A readme file is also included to provide some guidance. Abstract: Deployment of photovoltaics in space requires devices that combine high-efficiency, low areal mass, and resilience to harsh environments. Historically, high-efficiency multijunction III–V materials have dominated space power systems; however, their high cost and limited manufacturing throughput motivate the exploration of scalable alternatives. While CdTe-based thin-film photovoltaics offer an attractive option, their performance on non-conventional substrates can suffer from front-contact instability under higher-temperature processing. Here, the role of front-contact chemistry in limiting cell performance is investigated using CdTe-based devices fabricated on 150 μm thick Ceria-doped space-qualified 0214 Corning glass. A matrix of four transparent conducting oxides (TCOs: CTO, AZO, ITO, IZO) combined with two n-type emitters (MZO, IGO) reveals chemical stability at the front interface—rather than absorber composition alone—governs recombination losses, voltage deficits, and device reproducibility. Chemically stable front-contact combinations suppress elemental diffusion and interfacial degradation, resulting in significantly improved carrier lifetimes and junction quality. These insights are validated through record-certified Cd(Se,Te) cell efficiencies of 18.4% under AM1.5G and 16.2% under AM0 illumination on ultra-thin glass. Beyond CdTe, this work provides a general framework for the rational selection of TCO/emitter interfaces in superstrate thin-film photovoltaics, including emerging technologies like metal halide perovskites, while enabling high-efficiency, lightweight photovoltaics for space applications.

14 SOLAR ENERGY↗

Potential efficiencies of open- and closed-cycle CO, supersonic, electric-discharge lasers

Computed open- and closed-cycle system efficiencies (laser power output divided by electrical power input) are presented for a CW carbon monoxide, supersonic, electric-discharge laser. Closed-system results include the compressor power required to overcome stagnation pressure losses due to supersonic heat addition and a supersonic diffuser. The paper shows the effect on the system efficiencies of varying several important parameters. These parameters include: gas mixture, gas temperature, gas total temperature, gas density, total discharge energy loading, discharge efficiency, saturated gain coefficient, optical cavity size and location with respect to the discharge, and supersonic diffuser efficiency. Maximum open-cycle efficiency of 80-90% is predicted; the best closed-cycle result is 60-70%.

Monson, D. J.↗

Pilot line report: Development of a high efficiency thin silicon solar cell

Experimental technology advances were implemented to increase the conversion efficiency of ultrathin 2cm x 2cm cells, to demonstrate a capability for fabricating such cells at a rate of 10,000 per month, and to fabricate 200 large-area ultrathin cells to determine their feasibility of manufacture. A production rate of 10,000 50 micron m cells per month with lot average AM0 efficiencies of 11.5% was demonstrated, with peak efficiencies of 13.5% obtained. Losses in most stages of the processing were minimized, the remaining exceptions being in the photolithography and metallization steps for front contact generation and breakage handling. The 5cm x 5cm cells were fabricated with a peak yield in excess of 40% for over 10% AM0 efficiency. Greater fabrication volume is needed to fully evaluate the expected yield and efficiency levels for large cells.

Source record↗

Wind tunnel performance of four energy efficient propellers designed for Mach 0.8 cruise

Several advanced aerodynamic and acoustic concepts were investigated in recent wind tunnel tests performed in the NASA-Lewis Research Center 8x6 foot wind tunnel. These concepts included aerodynamically integrated propeller/nacelles, area-ruling, blade sweep, reduced blade thickness, and power (disk) loadings several times higher than conventional designs. Four eight-bladed propeller models were tested to determine aerodynamic performance. Relative noise measurements were made on three of the models at cruise conditions. Three of the models were designed with swept blades and one with straight blades. At the design Mach number of 0.8, power coefficient of 1.7, and advance ratio of 3.06, the straight bladed model had the lowest net efficiency of 75.8 percent. Increasing the sweep to 30 deg improved the performance to near 77 percent. Installation of an area-ruled spinner on a 30 deg sweep model further improved the efficiency to about 78 percent. The model with the highest blade sweep (45 deg) and an area-ruled spinner had the highest net efficiency of 78.7 percent, and at lower power loadings the efficiency exceeded 80 percent. At lower Mach numbers the 30 deg swept model had the highest efficiency. Values near 81 percent were obtained for the design loading at speeds to Mach 0.7. Relative noise measurements indicated that the acoustically designed 45 deg sweep model reduced the near field cruise noise by between 5 and 6 dB.

Jeracki, R. J.↗