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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Tundra SGS – Critical Importance of Site-Specific Injectivity Testing for Carbon Dioxide Injection Well Simulation Calibration

Paper presented at 16th International Conference on Greenhouse Gas Control Technologies (GHGT-16), October 23–27, 2022, Lyon, France. Brine injectivity tests were conducted on both the Broom Creek (BC) and Deadwood (DW) storage formations in one of the cored stratigraphic test wells prior to finalized simulations. The injectivity tests entailed injection of brine into the formations, followed by shutting in the wells. The shut-in duration represents the fall-off period which was used to carry out pressure transient analyses of the tests. The analysis of injectivity tests indicated that core-indicated and modeled permeability distributions should be conservatively multiplied by 2.5× and 5× in the BC and DW geologic models, respectively, prior to numerical simulations of CO 2 injection using Computer Modelling Group’s (CMG’s) GEM equation-of-state reservoir simulator. The scaler permeability multipliers allowed the fluid flow simulations to fully represent well test-measured injection well rates in the respective formations.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2014

Direct Utilization of Coal Syngas in High Temperature Fuel Cells

This EPSCoR project had two primary goals: (i) to build infrastructure and work force at WVU to support long-term research in the area of fuel cells and related sciences; (ii) study effects of various impurities found in coal-syngas on performance of Solid Oxide Fuel Cells (SOFC). As detailed in this report the WVU research team has made significant accomplishments in both of these areas. What follows is a brief summary of these accomplishments: State-of-the-art test facilities and diagnostic tools have been built and put into use. These include cell manufacturing, half-cell and full-cell test benches, XPS, XRD, TEM, Raman, EDAX, SEM, EIS, and ESEM equipment, unique in-situ measurement techniques and test benches (Environmental EM, Transient Mass-Spectrometer-MS, and IR Optical Temperature measurements). In addition, computational capabilities have been developed culminating in a multi-scale multi-physics fuel cell simulation code, DREAM-SOFC, as well as a Beowulf cluster with 64 CPU units. We have trained 16 graduate students, 10 postdoctoral fellows, and recruited 4 new young faculty members who have actively participated in the EPSCoR project. All four of these faculty members have already been promoted to the tenured associate professor level. With the help of these faculty and students, we were able to secure 14 research awards/contracts amounting to a total of circa $5.0 Million external funding in closely related areas of research. Using the facilities mentioned above, the effects of PH3, HCl, Cl2, and H2S on cell performance have been studied in detail, mechanisms have been identified, and also remedies have been proposed and demonstrated in the laboratory. For example, it has been determined that PH3 reacts rapidly with Ni to from secondary compounds which may become softer or even melt at high temperature and then induce Ni migration to the surface of the cell changing the material and micro-structural properties of the cell drastically. It is found that the extent of steam and current load accelerate the degradation caused by PH3. A unique filtering technique has been proposed to reduce the effect of PH3. In addition, various cell materials have been proposed to reduce the rate of degradation caused by H2S. Furthermore, a three-dimensional, transient multi-physics model has been formulated to describe primary transport processes and electro-chemical reactions occurring within the cell. This model has been validated using data gathered from accelerated tests. The validated model then has been used to study the degradation rates under a range of operating conditions and impurity levels. This has resulted in a procedure that uses both experiments and simulations to predict the life-time of a cell operating with syngas with known concentration of trace impurities. Finally all the experience and knowledge gained has been disseminated via 39 journal papers and 43 presentations/posters/conference papers.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2016

Simulation of IST Turbomachinery Power-Neutral Tests with the ANL Plant Dynamics Code

The validation of the Plant Dynamics Code (PDC) developed at Argonne National Laboratory (ANL) for the steady-state and transient analysis of supercritical carbon dioxide (sCO2) systems has been continued with new test data from the Naval Nuclear Laboratory (operated by Bechtel Marine Propulsion Corporation) Integrated System Test (IST). Although data from three runs were provided to ANL, only two of the data sets were analyzed and described in this report. The common feature of these tests is the power-neutral operation of the turbine-compressor shaft, where no external power through the alternator was provided during the tests. Instead, the shaft speed was allowed to change dictated by the power balance between the turbine, the compressor, and the power losses in the shaft. The new test data turned out to be important for code validation for several reasons. First, the power-neutral operation of the shaft allows validation of the shaft dynamics equations in asynchronous mode, when the shaft is disconnected from the grid. Second, the shaft speed control with the compressor recirculation (CR) valve not only allows for testing the code control logic itself, but it also serves as a good test for validation of both the compressor surge control and the turbine bypass control actions, since the effect of the CR action on the loop conditions is similar for both of these controls. Third, the varying compressor-inlet temperature change test allows validation of the transient response of the precooler, a shell-and-tube heat exchanger. The first transient simulation of the compressor-inlet temperature variation Test 64661 showed a much slower calculated response of the precooler in the calculations than the test data. Further investigation revealed an error in calculating the heat exchanger tube mass for the PDC dynamic equations that resulted in a slower change in the tube wall temperature than measured. The transient calculations for both tests were done in two steps. The first step was done in the same fashion as the FY15 IST analysis, where the CR valve position and the turbine-compressor shaft speed were specified through the PDC input based on the test values. On the second step, the turbine-compressor shaft dynamics equations were invoked by specifying that the shaft is disconnected from the grid. In addition, the CR valve control was used to control the shaft speed, based on the turbine bypass control logic already implemented in the PDC. For the shaft power balance, the friction (windage) loss is calculated based on the shaft balance at the steady-state conditions and is assumed to be scaled to the third power of shaft speed in the transient. Both the steady-state and transient simulations of both tests showed good agreement with the test data. The only significant difference was the turbine performance, which was not predicted as well as it was in the previous IST simulation, resulting in the prediction of a somewhat different flow split between the two turbines. This flow split difference is believed to be the result of not addressing the recent turbine modifications in the model. In addition, the full simulation of the turbine-compressor speed variation Test 65261-P with shaft speed control showed greater a difference with the test data later in the transient than the other test. Further analysis of the results revealed that this difference is most likely due to scaling the shaft windage losses only with the shaft speed and ignoring its dependency on the fluid density in the shaft cavity. Based on the results of steady state and transient calculations of the Tests 64661 and 65216-P, several areas of future improvements for the PDC simulation of the IST are identified.

42 ENGINEERING↗
DOE OSTI2015

Inverter Ground Fault Overvoltage Testing

This report describes testing conducted at NREL to determine the duration and magnitude of transient overvoltages created by several commercial PV inverters during ground fault conditions. For this work, a test plan developed by the Forum on Inverter Grid Integration Issues (FIGII) has been implemented in a custom test setup at NREL. Load rejection overvoltage test results were reported previously in a separate technical report.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2022

Functional fiber-optic sensors embedded in stainless steel components using ultrasonic additive manufacturing for distributed temperature and strain measurements

The nuclear industry is progressing toward microreactors that can be factory assembled and deployed to remote regions for reliable, scalable power generation. However, the reduced power output requires enhanced monitoring capabilities to reduce staffing and eventually move toward autonomous control to improve the economics of microreactors. The ability to embed sensors such as fiber-optics, which can provide spatially distributed temperature and strain measurements, within microreactor components for real-time health monitoring would be particularly advantageous. Recent advances in ultrasonic additive manufacturing (UAM) have demonstrated the successful embedding of fiber-optics in soft materials such as Al and Cu by placing the sensors in machined cavities and ultrasonically welding over the top with thin foils. This article reports the first successful embedment of fiber-optic sensors and thermocouples within a common nuclear reactor material, SS304, via UAM. UAM parameters were first explored with simple plate geometries before moving to more complex geometries, such as pipes and other test articles for heat pipe–based microreactors. Select samples were sectioned for microscopy to evaluate the sensor/foil and foil/foil interfaces from samples fabricated by using 100% SS304 foils vs. foils plated with a Ni coating to improve UAM bonding. Furthermore, embedding metal-coated, low-bend loss fibers resulted in greatly reduced signal attenuation and adequate compressive residual strain in the embedded region to ensure successful strain coupling. Pipe specimen functional testing was performed by monitoring temperature and strain during transient and steady-state thermal testing.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Development and Standup Testing of a System to Observe Fission Gas Release During Transient Heating of Nuclear Fuel Element Segments

As part of an effort to increase the burnup of nuclear fuels used in Light Water Reactors, the mechanisms and timing of fission gas release during high temperature transients must be studied. In this work, a system was built to observe fission gas release of fuel element sections under evacuated conditions, at temperatures up to 800 °C. System capabilities and limitations are overviewed in this report. The system was further tested with a hydrogen-infused titanium foils and gas release was observed in agreement with literature observations. Pressure was monitored with two sensors, and temperature was monitored using a thermocouple and a pyrometer with continuous visual imaging.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Diesel Oxidation Catalyst Performance with Biodiesel Formulations

Biodiesel (i.e., mono-alkyl esters of long chain fatty acids derived from vegetable oils and animal fats) is a renewable diesel fuel providing life-cycle greenhouse gas emission reductions relative to petroleum-derived diesel. With the expectation that there would be widespread use of biodiesel as a substitute for ultra-low sulfur diesel (ULSD), there have been many studies looking into the effects of biodiesel on engine and aftertreatment, particularly its compatibility to the current aftertreatment technologies. The objective of this study was to generate experimental data to measure the effectiveness of a current technology diesel oxidation catalysts (DOC) to oxidize soy-based biodiesel at various blend levels with ULSD. Biodiesel blends from 0 to 100% were evaluated on an engine using a conventional DOC. In the steady-state performance test where fuel dosing rate was increased at fixed DOC inlet temperature, B20 performed similarly to ULSD at the lowest flow rate or exhaust temperature over 340 degrees C for medium and high flows. B50 blends performed nearly as well under most conditions. Higher blends exhibited reduced thermal efficiency and DOC outlet temperature with increasing dosing rate under most conditions and required exhaust temperatures over 400 degrees C to achieve or nearly achieve performance similar to ULSD. In the steady-state light of test where fuel dosing rate is fixed but exhaust temperature is increased incrementally, B20 generally performed similarly to ULSD at the highest inlet temperature, with only minor deficiencies at lower temperatures. Higher blends exhibited lower thermal efficiency and did not achieve as high DOC outlet temperatures. In the transient light-off test light-off temperature for ULSD was typically less than 225 degrees C, while for B100 it ranged from 290 degrees C to 330 degrees C. Based on the data set, it can be concluded that biodiesel fuels have a higher light-off temperature primarily because of their higher boiling points, with a minor secondary impact of their lower energy content.

ADVANCED PROPULSION SYSTEMS,BIOMASS FUELS↗
DOE OSTI2017

Abstract - Cooperative Research and Development Agreement between AK Supply, Inc. and National Energy Technology Laboratory

The main goal of CRADA between AK Supply and NETL is to redesign the solid oxide fuel cell configuration for hybrid power generation systems for greater flexibility and operability. The new fuel cell design will consider incorporation of thermal energy storage into the fuel cell by modifying the material composition to increase the specific heat and/or the solid-solid phase transition and increasing the interconnect geometry (mass and volume) in the fuel cell. This developed technology will be tested using Hyper facility at NETL, Morgantown, to evaluate the performance in hybrid applications. Additionally, AK Supply and NETL will work on the development of a real-time, high temperature, intelligent micro-sensor for monitoring energy availability in the interconnect geometry. The will be used for control of stored energy release during load transients and will be tested on the NETL Hyper facility.

25 ENERGY STORAGE↗
DOE OSTI2012

Validation of the U.S. NRC coupled code system TRITON/TRACE/PARCS with the special power excursion reactor test III (SPERT III)

The Special Power Excursion Reactor Test III (SPERT III) was a series of reactivity insertion experiments conducted in the 1950's. This paper describes the validation of the U.S. NRC Coupled Code system TRITON/PARCS/TRACE to simulate reactivity insertion accidents (RIA) by using several of the SPERT III tests. The work here used the SPERT III E-core configuration tests in which the RIA was initiated by ejecting a control rod. The resulting super-prompt reactivity excursion and negative reactivity feedback produced the familiar bell shaped power increase and decrease. The energy deposition during such a power peak has important safety consequences and provides validation basis for core coupled multi-physics codes. The transients of five separate tests are used to benchmark the PARCS/TRACE coupled code. The models were thoroughly validated using the original experiment documentation. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2017

Anisotropic Thermal Response of Packed Copper Wire

The apparent thermal conductivity of packed copper wire test specimens was measured parallel and perpendicular to the axis of the wire using laser flash, transient plane source, and transmittance test methods. Approximately 50% wire packing efficiency was produced in the specimens using either 670- or 925-μm-diameter copper wires that both had an insulation coating thickness of 37 μm. The interstices were filled with a conventional varnish material and also contained some remnant porosity. The apparent thermal conductivity perpendicular to the wire axis was about 0.5–1 W/mK, whereas it was over 200 W/mK in the parallel direction. The Kanzaki model and an finite element analysis (FEA) model were found to reasonably predict the apparent thermal conductivity perpendicular to the wires but thermal conductivity percolation from nonideal wire-packing may result in their underestimation of it.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2017

The Development of Vocational Vehicle Drive Cycles and Segmentation

Under a collaborative interagency agreement between the U.S. Environmental Protection Agency and the U.S Department of Energy (DOE), the National Renewable Energy Laboratory (NREL) performed a series of in-depth analyses to characterize the on-road driving behavior including distributions of vehicle speed, idle time, accelerations and decelerations, and other driving metrics of medium- and heavy-duty vocational vehicles operating within the United States. As part of this effort, NREL researchers segmented U.S. medium- and heavy-duty vocational vehicle driving characteristics into three distinct operating groups or clusters using real world drive cycle data collected at 1 Hz and stored in NREL's Fleet DNA database. The Fleet DNA database contains millions of miles of historical real-world drive cycle data captured from medium- and heavy vehicles operating across the United States. The data encompass data from existing DOE activities as well as contributions from valued industry stakeholder participants. For this project, data captured from 913 unique vehicles comprising 16,250 days of operation were drawn from the Fleet DNA database and examined. The Fleet DNA data used as a source for this analysis has been collected from a total of 30 unique fleets/data providers operating across 22 unique geographic locations spread across the United States. This includes locations with topology ranging from the foothills of Denver, Colorado, to the flats of Miami, Florida. The range of fleets, geographic locations, and total number of vehicles analyzed ensures results that include the influence of these factors. While no analysis will be perfect without unlimited resources and data, it is the researchers understanding that the Fleet DNA database is the largest and most thorough publicly accessible vocational vehicle usage database currently in operation. This report includes an introduction to the Fleet DNA database and the data contained within, a presentation of the results of the statistical analysis performed by NREL, review of the logistic model developed to predict cluster membership, and a discussion and detailed summary of the development of the vocational drive cycle weights and representative transient drive cycles for testing and simulation. Additional discussion of known limitations and potential future work are also included in the report content.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2018

Investigation of the Impact of Fuel Properties on Particulate Number Emission of a Modern Gasoline Direct Injection Engine

Gasoline Direct Injection (GDI) has become the preferred technology for spark-ignition engines resulting in greater specific power output and lower fuel consumption, and consequently reduction in CO2 emission. However, GDI engines face a substantial challenge in meeting new and future emission limits, especially the stringent particle number (PN) emissions recently introduced in Europe and China. Studies have shown that the fuel used by a vehicle has a significant impact on engine out emissions. In this study, nine fuels with varying chemical composition and physical properties were tested on a modern turbo-charged side-mounted GDI engine with design changes to reduce particulate emissions. The fuels tested included four fuels meeting US certification requirements; two fuels meeting European certification requirements; and one fuel meeting China 6 certification requirements being proposed at the time of this work. Two risk safeguard fuels (RSG), representing the properties of worst case market fuels in Europe and China, were also included. The particle number concentration of the solid particulates was measured in the engine-out exhaust flow at steady state engine operations with load and speed sweeps, and semi-transient load steps. The test results showed a factor of 6 PN emission difference among all certification fuels tested. Combined with detailed fuel analyses, this study evaluated important factors (such as oxygenates, carbon chain length and thermo-physical properties) that cause PN emissions which were not included in PMI index. A linear regression was performed to develop a PN predictive model which showed improved fitting quality than using PMI.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2011

Male Sterile2 Encodes a Plastid-Localized Fatty Acyl Carrier Protein Reductase Required for Pollen Exine Development in Arabidopsis

Male Sterile2 (MS2) is predicted to encode a fatty acid reductase required for pollen wall development in Arabidopsis (Arabidopsis thaliana). Transient expression of MS2 in tobacco (Nicotiana benthamiana) leaves resulted in the accumulation of significant levels of C16 and C18 fatty alcohols. Expression of MS2 fused with green fluorescent protein revealed that an amino-terminal transit peptide targets the MS2 to plastids. The plastidial localization of MS2 is biologically important because genetic complementation of MS2 in ms2 homozygous plants was dependent on the presence of its amino-terminal transit peptide or that of the Rubisco small subunit protein amino-terminal transit peptide. In addition, two domains, NAD(P)H-binding domain and sterile domain, conserved in MS2 and its homologs were also shown to be essential for MS2 function in pollen exine development by genetic complementation testing. Direct biochemical analysis revealed that purified recombinant MS2 enzyme is able to convert palmitoyl-Acyl Carrier Protein to the corresponding C16:0 alcohol with NAD(P)H as the preferred electron donor. Using optimized reaction conditions (i.e. at pH 6.0 and 30 C), MS2 exhibits a K{sub m} for 16:0-Acyl Carrier Protein of 23.3 {+-} 4.0 {mu}m, a V{sub max} of 38.3 {+-} 4.5 nmol mg{sup -1} min{sup -1}, and a catalytic efficiency/K{sub m} of 1,873 m{sup -1} s{sup -1}. Based on the high homology of MS2 to other characterized fatty acid reductases, it was surprising that MS2 showed no activity against palmitoyl- or other acyl-coenzyme A; however, this is consistent with its plastidial localization. In summary, genetic and biochemical evidence demonstrate an MS2-mediated conserved plastidial pathway for the production of fatty alcohols that are essential for pollen wall biosynthesis in Arabidopsis.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2018

Advanced SOFC quality control and the role of manufacturing defects on stack reliability

Atrex Energy rolled out first commercial SOFC generator products in 2013. Following that we embarked on implementation of mass production in order to ramp up productivity and lower the costs in the meantime. To ensure the goal of mass production, an accurate, cost effective and consistent quality control methodology needs to be in place. The aim of this DOE funded project is to devise a machine and methodology for cell quality control using modern non-destructive testing methods and cell rejection criterion based on the empirical determination of the role of manufacturing flaws on stack degradation and reliability. The work scope encompasses two goals aimed at 1) developing automatable techniques for objective flaw detection and 2) developing an understanding of the ramifications of flaws on stack and cell reliability. By accomplishing these two goals it is likely that an advanced stage Quality Control (QC) device can be developed. This project scope encompasses: 1) Invention of a high speed automated instrument for spatial mapping of surface and sub-surface imperfections in production cells (ex situ) using modern imaging techniques. 2) Identification of rejection criteria upon which to screen cells from production by: a. Magnification of the effect of production defects on cell degradation through fabrication and testing of micro-cells which encompass these imperfections. b. The long term testing of full size production cells both as single cells and in small stacks, in order to correlate the (in situ) performance and degradation with the imperfection type (identified ex-situ) and hence be able to classify imperfections as actual defects. We first built a defect library with the cells containing imperfections classified and documented. The cells with various imperfections were tested to evaluate the imperfection potential impact on cell electrochemical performance. Evaluations were conducted on minicell, single cell and stack levels. On minicell level, pinhole, scratch, crack, contamination, and pop-out were investigated. We found: (1) none of the imperfections causes calamity type failure, (2) pinholes do not show measurable effect on minicell performance, (3) imperfection such as electrolyte abrasion, scratch, and pop out cause minicell potential to fluctuate by different degrees; the cells with such imperfections exhibit sensitivity of potential to high fuel utilization and “self healing” behavior. On single cell level we evaluated the effect of long crack and high population pinholes. The cell with a long crack does not show performance compromise at start. There is no potential fluctuation or sensitivity to high fuel utilization or catastrophic failure. The voltage degradation due to thermal cycle is slightly higher than normal cells. The cells with high population pinholes perform surprisingly as well as normal cells over a period of 3,500h. Even when subjected to cyclic load condition, the cells 4 show negligible degradation. Our cells appear to have “self immunization” feature which fends off the adversary effects of certain imperfections. Defects were also evaluated on stack level. Two stacks were made each with ten defect cells. The first stack was tested for 13,2000h under steady load condition while the second was tested for 9,000h under transient load conditions. We found: (1) voltage fluctuation and sensitivity to thermal cycle were not observed in contrast to minicell test, (2) of the various cracks examined, including longitudinal cracks, circumferential crack, crack near closed and open ends, none exhibited distinguishable impact on performance, (3) defect cells exhibited higher degradation rates on average under steady load condition; Individually some defect cells performed similarly or better than reference cells, (4) under steady load condition all the cells degrade monotonically with degradation rate increasing with time, (5) under cyclic (transient) load condition, both defect and reference cells exhibit complex dynamic behaviors, (6) fuel loss (leak) was measured occasionally for stack 1, the cells with crack showed the highest fuel loss increase, nevertheless, no correlation with performance degradation could be established with certainty, and (7) no catastrophic failure ever happened other than incremental degradation. Posttest inspection and microanalysis were carried out; the observations are summarized in what follows: (1) Electrolyte pinholes, some scratches and IC porosity became undetectable after testing. (2) The cathode covering the popout defects is intact without any cracking or delamination. (3) The scratch was covered by cathode in pristine state; Ni oxide or NiO-YSZ filled the space where electrolyte was missing. After >10,000h operation, the cathode that used to cover the scratch was missing but the size of the scratch remains unchanged; there is a fairly dense Ni oxide layer on top of the scratch. (4) All of the cracks remain their original dimensions. Current collector kept longitudinal cracks closed which mitigated the adversary effect of crack on cell performance/durability. (5) The crack at open end showed some deterioration manifested by a small oxidation zone in the vicinity of the crack. Wide spectrum of imaging techniques were surveyed and evaluated to detect tubular SOFC defects. Optical methods, with and without assistance of expression technique, were applied to detect all kinds of defects. Thermograph method in combination of CO2 leak, ultra-sound and electric potential was also extensively evaluated to detect surface and under-surface defects such as short circuit. Based on these works, laser camera has been selected to build the final QC machine vision inspection system. The Gocator laser profile sensor was setup to generate 2D surface intensity images of tubular SOFC surface which were analyzed with Sherlock machine vision software supplied by Teledyne Dalsa. The Gocator output was integrated with the Sherlock software and enabled live images to be imported by a Common Vision Blox driver. The Sherlock software was programmed to detect various surface defects from the surface intensity images generated by the Gocator. These measurements are subsequently used to make pass or fail decisions.

01 COAL, LIGNITE, AND PEAT↗