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At least 55 records · Page 3

Cogeneration Technology Alternatives Study (CTAS). Volume 3: Industrial processes

Cogenerating electric power and process heat in single energy conversion systems rather than separately in utility plants and in process boilers is examined in terms of cost savings. The use of various advanced energy conversion systems are examined and compared with each other and with current technology systems for their savings in fuel energy, costs, and emissions in individual plants and on a national level. About fifty industrial processes from the target energy consuming sectors were used as a basis for matching a similar number of energy conversion systems that are considered as candidate which can be made available by the 1985 to 2000 time period. The sectors considered included food, textiles, lumber, paper, chemicals, petroleum, glass, and primary metals. The energy conversion systems included steam and gas turbines, diesels, thermionics, stirling, closed cycle and steam injected gas turbines, and fuel cells. Fuels considered were coal, both coal and petroleum based residual and distillate liquid fuels, and low Btu gas obtained through the on site gasification of coal. An attempt was made to use consistent assumptions and a consistent set of ground rules specified by NASA for determining performance and cost. Data and narrative descriptions of the industrial processes are given.

Palmer, W. B.↗

Cogeneration Technology Alternatives Study (CTAS). Volume 2: Comparison and evaluation of results

CTAS compared and evaluated various advanced energy conversion systems that can use coal or coal-derived fuels for industrial cogeneration applications. The principal aim of the study was to provide information needed by DOE to establish research and development (R&D) funding priorities for advanced-technology systems that could significantly advance the use of coal or coal-derived fuels in industrial cogeneration. Steam turbines, diesel engines, open-cycle gas turbines, combined cycles, closed-cycle gas turbines, Stirling engines, phosphoric acid fuel cells, molten carbonate fuel cells, and thermionics were studied with technology advancements appropriate for the 1985-2000 time period. The various advanced systems were compared and evaluated for a wide diversity of representative industrial plants on the basis of fuel energy savings, annual energy cost savings, emissions savings, and rate of return on investment (ROI) as compared with purchasing electricity from a utility and providing process heat with an on-site boiler.

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Physics-Guided Deep Learning for Complex System Health Management and Decision Making

The landscape of complex engineered systems is rapidly evolving, from smart manufacturing facilities to next-generation transportation vehicles. As these systems become increasingly sophisticated and interconnected, the need for advanced health management systems grows ever more critical. These systems must go beyond simple monitoring, actively predicting potential failures before they occur. This paradigm shift from fixed maintenance schedules to condition-based predictions is key to optimizing system performance, enhancing safety, and paving the way for autonomous decision-making across various industries. Whether in industrial processes, energy systems, or advanced transportation, the ability to anticipate and prevent failures is becoming a cornerstone of operational excellence. To accurately predict the future health of any complex system, knowledge of its current health state and future operational conditions is essential. Recent advancements in data-driven algorithms have generated growing interest in artificial intelligence for industrial applications. However, the limitations of pure data-driven methods, particularly in industries where data acquisition is costly and limited, have become apparent. This has led to a focus on blending physics with data-driven algorithms, mitigating the drawbacks of both approaches while emphasizing their respective advantages. This research proposes a novel framework for integrating physics-based performance models with deep learning algorithms for the prognostics of complex safety-critical systems. In this approach, physics-based models serve as a blueprint, capturing fundamental system behaviors, while deep learning algorithms, leveraging real-world sensor data, fill in gaps and identify subtle patterns indicative of potential problems. This hybrid methodology, utilizing techniques such as Physics-Informed Neural Networks (PINNs), offers a powerful solution for predicting system health. By fusing domain knowledge with data-driven insights, this approach promises more accurate, adaptable, and reliable models for health prediction. The resulting framework is versatile, applicable across various sectors including aerospace, manufacturing, and energy systems, ultimately contributing to safer, more efficient operations in our increasingly complex technological landscape.

Diagnostics↗

Energy Conversion Alternatives Study (ECAS)

ECAS compared various advanced energy conversion systems that can use coal or coal-derived fuels for baseload electric power generation. It was conducted in two phases. Phase 1 consisted of parametric studies. From these results, 11 concepts were selected for further study in Phase 2. For each of the Phase 2 systems and a common set of ground rules, performance, cost, environmental intrusion, and natural resource requirements were estimated. In addition, the contractors defined the state of the associated technology, identified the advances required, prepared preliminary research and development plans, and assessed other factors that would affect the implementation of each type of powerplant. The systems studied in Phase 2 include steam systems with atmospheric- and pressurized-fluidized-bed boilers; combined cycle gas turbine/steam systems with integrated gasifiers or fired by a semiclean, coal derived fuel; a potassium/steam system with a pressurized-fluidized-bed boiler; a closed-cycle gas turbine/organic system with a high-temperature, atmospheric-fluidized-bed furnace; a direct-coal-fired, open- cycle magnetohydrodynamic/steam system; and a molten-carbonate fuel cell/steam system with an integrated gasifier. The sensitivity of the results to changes in the ground rules and the impact of uncertainties in capital cost estimates were also examined.

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Advanced subsystems development

The concept design for a small (less than 10 MWe) solar thermal electric generating plant was completed using projected 1985 technology. The systems requirements were defined and specified. The components, including an engineering prototype for one 15 kWe module of the generating plant, were conceptually designed. Significant features of the small solar thermal power plant were identified as the following: (1) 15 kWe Stirling-cycle engine/alternator with constant power output; (2) 10 meter point-focusing paraboloidal concentrator with cantilevered cellular glass reflecting panels; (3) primary heat pipe with 800 C output solar cavity receiver; (4) secondary heat pipe with molten salt thermal energy storage unit; (5) electric energy transport system; and (6) advanced battery energy storage capability.

Livingston, F. R.↗

Energy Conversion Alternatives Study (ECAS), Westinghouse phase 1. Volume 2: Materials considerations

Extensive studies are presented which were carried out on materials behavior in nine advanced energy conversion systems employing coal and coal-derived fuels. The areas of materials behavior receiving particular attention in this regard are: (1) fireside corrosion and erosion in boiler and heat exchanger materials, (2) oxidation and hot corrosion of gas turbine materials, (3) liquid metal corrosion and mass transport, (4) high temperature steam corrosion, (5) compatability of materials with coal slag and MHD seed, (6) reaction of materials with impure helium, (7) allowable stresses for boiler and heat exchanger materials, (8) environmental effects on mechanical properties, and (9) liquid metal purity control and instrumentation. Such information was then utilized in recommending materials for use in the critical components of the power systems, and at the same time to identify materials problem areas and to evaluate qualitatively the difficulty of solving those problems. Specific materials recommendations for critical components of the nine advanced systems under study are contained in summary tables.

Thomas, D. E.↗

Performance and economic risk evaluation of dispersed solar thermal power systems by Monte Carlo simulation

A preliminary comparative evaluation of dispersed solar thermal power plants utilizing advanced technologies available in 1985-2000 time frame is under way at JPL. The solar power plants of 50 KWe to 10 MWe size are equipped with two axis tracking parabolic dish concentrator systems operating at temperatures in excess of 1000 F. The energy conversion schemes under consideration include advanced steam, open and closed cycle gas turbines, stirling, and combined cycle. The energy storage systems include advanced batteries, liquid metal, and chemical. This paper outlines a simple methodology for a probabilistic assessment of such systems. Sources of uncertainty in the development of advanced systems are identified, and a computer Monte Carlo simulation is exercised to permit an analysis of the tradeoffs of the risk of failure versus the potential for large gains. Frequency distribution of energy cost for several alternatives are presented.

Manvi, R.↗

Comparative Evaluation of Phase 1 Results from the Energy Conversion Alternatives Study (ECAS)

Ten advanced energy conversion systems for central-station, based-load electric power generation using coal and coal-derived fuels which were studied by NASA are presented. Various contractors were selected by competitive bidding to study these systems. A comparative evaluation is provided of the contractor results on both a system-by-system and an overall basis. Ground rules specified by NASA, such as coal specifications, fuel costs, labor costs, method of cost comparison, escalation and interest during construction, fixed charges, emission standards, and environmental conditions, are presented. Each system discussion includes the potential advantages of the system, the scope of each contractor's analysis, typical schematics of systems, comparison of cost of electricity and efficiency for each contractor, identification and reconciliation of differences, identification of future improvements, and discussion of outside comments. Considerations common to all systems, such as materials and furnaces, are also discussed. Results of selected in-house analyses are presented, in addition to contractor data. The results for all systems are then compared.

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Energy Conservation Alternatives Study (ECAS): Conceptual Design and Implementation Assessment of a Utility Steam Plant with Conventional Furnace and Wet Lime Stack Gas Scrubbers

A study was performed to estimate the technical/economic characteristics of a steam power plant (3500 pounds per square inch gauge, 1000 degrees Fahrenheit / 1000 degrees Fahrenheit) with a coal-burning radiant furnace and a wet lime stack gas scrubber to control sulfur emissions. Particulate emissions were controlled by an electrostatic precipitator operating at 300 degrees Fahrenheit. The stack gas from the scrubber was reheated from 125 degrees Fahrenheit to 250 degrees Fahrenheit as a base case, and from 125 degrees Fahrenheit to 175 degrees Fahrenheit as an alternate case. The study was performed on a basis consistent with the General Electric ECAS Phase II evaluation of advanced energy conversion systems for electric utility baseload applications using coal or coal-derived fuels. A conceptual design of the power plant was developed, including the on-site calcination of limestone to lime and the provision of sludge ponds to store the products of flue gas scrubbing. From this design, estimates were derived for power plant efficiency, capital cost, environmental intrusion characteristics, natural resource requirements, and cost of electricity at an assumed capacity factor of 65 percent. An implementation assessment was performed where factors affecting applicability of the conceptual design power plant in electric utility generation systems were appraised. At 250 degrees Fahrenheit and 175 degrees Fahrenheit stack gas temperatures respectively, the plants showed a cost of electricity of 39.8 and 37.0 mills per kilowatt-hours and overall plant efficiencies of 32 percent and 34 percent.

Brown, Dale H.↗

Cogeneration Technology Alternatives Study (CTAS). Volume 2: Analytical approach

The use of various advanced energy conversion systems were compared with each other and with current technology systems for their savings in fuel energy, costs, and emissions in individual plants and on a national level. The ground rules established by NASA and assumptions made by the General Electric Company in performing this cogeneration technology alternatives study are presented. The analytical methodology employed is described in detail and is illustrated with numerical examples together with a description of the computer program used in calculating over 7000 energy conversion system-industrial process applications. For Vol. 1, see 80N24797.

Gerlaugh, H. E.↗

Cogeneration Technology Alternatives Study (CTAS). Volume 6: Computer data. Part 1: Coal-fired nocogeneration process boiler, section A

Various advanced energy conversion systems (ECS) are compared with each other and with current technology systems for their savings in fuel energy, costs, and emissions in individual plants and on a national level. About fifty industrial processes from the largest energy consuming sectors were used as a basis for matching a similar number of energy conversion systems that are considered as candidates which can be made available by the 1985 to 2000 time period. The sectors considered included food, textiles, lumber, paper, chemicals, petroleum, glass, and primary metals. The energy conversion systems included steam and gas turbines, diesels, thermionics, stirling, closed cycle and steam injected gas turbines, and fuel cells. Fuels considered were coal, both coal and petroleum based residual and distillate liquid fuels, and low Btu gas obtained through the on-site gasification of coal. Computer generated reports of the fuel consumption and savings, capital costs, economics and emissions of the cogeneration energy conversion systems (ECS's) heat and power matched to the individual industrial processes are presented for coal fired process boilers. National fuel and emissions savings are also reported for each ECS assuming it alone is implemented.

Knightly, W. F.↗

Recrystallization and grain growth in NiAl

Aluminide intermetallics, because of their strength, microstructural stability, and oxidation resistance at elevated temperatures, represent potential structural materials for use in advanced energy conversion systems. This inherent potential of the intermetallics can currently not be realized in connection with the general brittleness of the materials under ambient conditions. It is pointed out, however, that brittleness is not an inherent characteristic. Single crystals are ductile and polycrystals may be, too, if their grains are fine enough. The present investigation is concerned with an approach for reducing material brittleness, taking into account thermal-mechanically induced grain refinement in NiAl, a B2 aluminide which melts at 1638 C and which retains complete order to its melting point. Attention is given to the kinetics of recrystallization and grain growth of warm-worked, nickel-rich material.

Haff, G. R.↗

High power bipolar lead-acid batteries

The Jet Propulsion Laboratory (JPL), with interest in advanced energy storage systems, is involved in the development of a unique lead acid battery design. This battery utilizes the same combination of lead and lead dioxide active materials present in the automobile starting battery. However, it can provide 2 to 10 times the power while minimizing volume and weight. The typical starting battery is described as a monopolar type using one current collector for both the positive and negative plate of adjacent cells. Specific power as high as 2.5 kW/kg was projected for 30 second periods with as many as 2000 recharge cycles.

Halpert, Gerald↗

Chemochromic Hydrogen Leak Detectors

At NASA, hydrogen safety is a key concern for space shuttle processing. Leaks of any level must be quickly recognized and addressed due to hydrogen s lower explosion limit. Chemo - chromic devices have been developed to detect hydrogen gas in several embodiments. Because hydrogen is odorless and colorless and poses an explosion hazard, there is an emerging need for sensors to quickly and accurately detect low levels of leaking hydrogen in fuel cells and other advanced energy- generating systems in which hydrogen is used as fuel. The device incorporates a chemo - chromic pigment into a base polymer. The article can reversibly or irreversibly change color upon exposure to hydrogen. The irreversible pigment changes color from a light beige to a dark gray. The sensitivity of the pigment can be tailored to its application by altering its exposure to gas through the incorporation of one or more additives or polymer matrix. Furthermore, through the incorporation of insulating additives, the chemochromic sensor can operate at cryogenic temperatures as low as 78 K. A chemochromic detector of this type can be manufactured into any feasible polymer part including injection molded plastic parts, fiber-spun textiles, or extruded tapes. The detectors are simple, inexpensive, portable, and do not require an external power source. The chemochromic detectors were installed and removed easily at the KSC launch pad without need for special expertise. These detectors may require an external monitor such as the human eye, camera, or electronic detector; however, they could be left in place, unmonitored, and examined later for color change to determine whether there had been exposure to hydrogen. In one type of envisioned application, chemochromic detectors would be fabricated as outer layers (e.g., casings or coatings) on high-pressure hydrogen storage tanks and other components of hydrogen-handling systems to provide visible indications of hydrogen leaks caused by fatigue failures or other failures in those systems. In another type of envisioned application, chemochromic detectors of this type could be optoelectronically instrumented for monitoring to provide measured digital indications of color changes indicative of the presence of hydrogen.

Roberson, Luke↗

New Class of Flow Batteries for Terrestrial and Aerospace Energy Storage Applications

Future sustainable energy generation technologies such as photovoltaic and wind farms require advanced energy storage systems on a massive scale to make the alternate (green) energy options practical. The daunting requirements of such large-scale energy systems such as long operating and cycle life, safety, and low cost are not adequately met by state-of-the-art energy storage technologies such as vanadium flow cells, lead-acid, and zinc-bromine batteries. Much attention is being paid to redox batteries specifically to the vanadium redox battery (VRB) due to their simplicity, low cost, and good life characteristics compared to other related battery technologies. NASA is currently seeking high-specific- energy and long-cycle-life rechargeable batteries in the 10-to-100-kW range to support future human exploration missions, such as planetary habitats, human rovers, etc. The flow batteries described above are excellent candidates for these applications, as well as other applications that propose to use regenerative fuel cells. A new flow cell technology is proposed based on coupling two novel electrodes in the form of solvated electron systems (SES) between an alkali (or alkaline earth) metal and poly aromatic hydrocarbons (PAH), separated by an ionically conducting separator. The cell reaction involves the formation of such SES with a PAH of high voltage in the cathode, while the alkali (or alkaline earth metal) is reduced from such an MPAH complex in the anode half-cell. During recharge, the reactions are reversed in both electrodes. In other words, the alkali (alkaline earth) metal ion simply shuttles from one M-PAH complex (SES) to another, which are separated by a metal-ion conducting solid or polymer electrolyte separator. As an example, the concept was demonstrated with Li-naphthalene//Li DDQ (DDQ is 2,3-Dichloro-5,6-dicyano- 1,4-benzoquinone) separated by lithium super ion conductor, either ceramic or polymer (solid polymer or gel polymer) electrolytes. The reactants are Li-naphthalene dissolved in tetrahydrofuran (THF) with a lithium salt of 1M LiBF4 (lithium tetra fluoroborate) in the anode compartment, and DDQ again dissolved in THF and also containing 1M LiBF4 salt in the cathode half-cell. The solid electrolyte separator used in the first set of experiments is a ceramic solid electrolyte, available from a commercial source. The open circuit voltage of the cells is close to 3.0 V, as expected from the individual half-cell voltages of Li-naphthalene and Li-DDQ. Upon discharge, the cell shows steady discharge voltage of 2.7 V, which confirms that the electrochemical processes do involve lithium ion shuttling from the anodic compartment to the cathode half-cell. The reversibility or rechargeability is demonstrated by charging the partially discharged cells (i.e., with lithium present in the DDQ half). Once again, a steady voltage close to 3.0 V was observed during charge, indicating that the system is quite reversible. In the subsequent concept-demonstration studies, the ceramic electrolyte has been replaced with a gel polymer electrolyte, e.g., PVDF-HFP (poly vinylene difluoride hexafluoropropene) gel, which has several advantages such as high ionic conductivity (almost comparable to liquid electrolyte and about 2 orders of magnitude better than the ceramic equivalent), lower cost, and possibly higher chemical stability at the anode. In addition, it can be bonded to the electrode by thermal fusion to form membrane electrode assemblies (MEAs), as is done in fuel cells.

Bugga, Ratnakumar V.↗

Development of Solid State Electrolytes for Li-Metal Based High Capacity Battery

NASA future missions demand safe, high specific energy (>400 Wh/kg) batteries. Current state-of-the-art (SOA) lithium-ion batteries (LIBs) can only provide ~150-200 Wh/kg in energy capacity, which is unable to meet NASA's future energy goals, and also pose safety issues due to the use of liquid flammable electrolyte. There are intense on-going development activities to increase battery energy density. The use of Li metal as an anode material has emerged as one highly attractive option for achieving high-energy, next generation batteries. This is because Li has many advantages. It is the lightest metal, but also has the highest theoretical capacity. It also has the lowest potential, which boosts whole cell voltage, and Li metal is 100% active material and requires no binder. Thus, Li metal is an ideal anode material for high energy battery chemistries. Lithium metal based advanced battery chemistries are envisioned to be mission enhancing and, in many cases, mission enabling for future space and aeronautic applications. However, the reliable use of this exceptionally high capacity anode in a commercial rechargeable battery has not been achieved due to safety and reliability concerns resulting from thermal runaway and short-circuit issues due to dendritic growth on the Li metal anode from lithium plating during charge-discharge cycles. A solid state electrolyte, such as garnet/ceramic or solid polymer nanocomposite electrolyte, is a promising approach to make Li metal safely cycling. The solid state electrolyte is non-flammable and eliminates leakage and fire hazard by replacing the liquid flammable electrolyte. However, the low-ionic conductivity and high interfacial impedance are the key issues to be overcome. In this presentation, the research activities on solid state electrolyte development funded by the NASA Advanced Energy Storage System program and by the NASA Center Innovative Fund will be presented, and the progress and results will be also discussed.

Wu, James J.↗

Assessment of the potential of solar thermal small power systems in small utilities

The potential economic benefit of small solar thermal electric power systems to small municipal and rural electric utilities is assessed. Five different solar thermal small power system configurations were considered in three different solar thermal technologies. The configurations included: (1) 1 MW, 2 MW, and 10 MW parabolic dish concentrators with a 15 kW heat engine mounted at the focal point of each dish, these systems utilized advanced battery energy storage; (2) a 10 MW system with variable slat concentrators and central steam Rankine energy conversion, this system utilized sensible thermal energy storage; and (3) a 50 MW central receiver system consisting of a field of heliostats concentrating energy on a tower-mounted receiver and a central steam Rankine conversion system, this system also utilized sensible thermal storage. The results are summarized in terms of break-even capital costs. The break-even capital cost was defined as the solar thermal plant capital cost which would have to be achieved in order for the solar thermal plants to penetrate 10 percent of the reference small utility generation mix by the year 2000. The calculated break-even capital costs are presented.

Steitz, P.↗