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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 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

The Staged, Pressurized Oxy-Combustion Technology: Status and Application to Boiler Retrofits to Yield Carbon-Negative Power via Biomass

Recognizing the benefits of pressurization and fuel staging on the efficiency of oxy-combustion, the staged, pressurized oxy-combustion (SPOC) process was introduced in 2012. The combination of fuel staging and pressurized oxy-combustion results in a more compact plant, a higher plant efficiency and reduced costs for pollutant and greenhouse gas removal compared with plants equipped with conventional carbon capture. This approach to power generation enables a modular boiler design and optimizes the plant for flexible operation, which is essential to meet the demands of the modern grid when it contains intermittent power sources. Originally designed to burn coal, the SPOC process is well-suited for biomass because the combustion of biomass leads to a high moisture content in the flue gas and the SPOC process is able to recover the latent heat of this moisture, enhancing system performance over that of traditional biomass combustion at atmospheric pressure. The present work is focused on evaluating the potential for utilizing the SPOC process in retrofit applications wherein the boilers of an existing plant are replaced with the SPOC process, and woody biomass is used as the fuel to yield carbon-negative power. Two applications are considered: power generation and cogeneration (heat and power). Modeling these systems in Aspen Plus demonstrates that the SPOC process surpasses the performance of baseline plants with post-combustion capture (PCC) for both power generation and cogeneration. Specifically, compared to a PCC equipped plant, the SPOC power plant has 33% higher efficiency, and the SPOC cogeneration plant reaches 42% higher net energy. Experimentally, the existing SPOC facility was fired for the first time with 100% biomass and after minor improvements were made to the feeding system, the facility demonstrated excellent performance during startup, steady-state operation and turndown.

Carbon capture and storage↗
DOE OSTI2020

Effect of Thermal Storage on the Emissions and Efficiency Performance of a Wood Pellet-Fired Residential Boiler

Wood pellet boilers for residential heating applications offer the promise of low emissions, high efficiency, and automatic operation. However, when operated in the field, these units operate often at very low loads causing them to cycle. In this study, the performance of a 25-kW modern pellet boiler under emulated field conditions and fixed nominal loads of 15% and 100% has been studied in a lab—with and without a buffer tank. A dilution tunnel approach was used for the measurement of particulate emissions, in accordance with U.S. certification testing requirements under EPA Methods 28 WHH and 28 WHH PTS. Results show that increasing the amount of thermal storage used decreases cycling rates leading to decreased emissions and increased efficiency. Without thermal storage, integrated efficiency over a 15% load test period was 57%, compared to 74% when thermal storage was used. Particulate emissions were 180 mg/MJ and 64 mg/MJ for the 15% load case without and with thermal storage, respectively.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Equivalent Safety Evaluation of the 2021 Edition of the ASME Boiler and Pressure Vessel Code to Editions Incorporated by Reference in 49 CFR 192, 193, and 195

Federal safety standards for natural gas and hazardous liquid pipelines and liquid natural gas facilities incorporate rules and requirements for boiler and pressure vessel design and fabrication into 49 CFR Parts 192, 193, and 195 through the IBR process. The equivalent safety evaluations documented in this report demonstrate that boilers and pressure vessels in pipeline facilities that are designed and fabricated in accordance with rules and requirements specified in the 2021 edition do not violate the fundamental safety assumptions stated or implied in the 2007 edition of the ASME BPVC and therefore provide equivalent safety.

03 NATURAL GAS↗
DOE OSTI2023

An Integrated Approach to Predicting Ash Deposition and Heat Transfer in Coal-Fired Boilers

The overall goal of this project is to develop via measurements and simulations an advanced online technology to predict, monitor and manage fireside ash deposition in a coal-fired boiler allowing for more efficient operations under a range of load conditions and fuel property variability. With this in place fuel sorting and blending can be done upstream and operations can be optimized to compensate for load and fuel properties. In support of this objective, three experimental campaigns were undertaken during the course of the project to measure ash deposition rates within the boiler at different fuel flow rates and its ash composition variability. Simulations of the experimental conditions representing actual geometry, operational scenarios in terms of air flow rates, coal flow rates as well as coal compositions, heating values, and particle size distributions were also carried out. Deposition rates were predicted using a unique particle kinetic energy and viscosity based ash deposition methodology whose validity was ascertained by comparing against deposition rate measurements for widely varying operating conditions and ash compositions in a lab-scale furnace. With a unique end-to-end combustion modeling methodology established and different simulation scenarios carried out, the results from our computational fluid dynamic (CFD) simulations in conjunction with the plant data summarized in this report were used to refine Microbeam Technology Incorporated’s MTI CSPI-CT Tool to predict and monitor fire-side ash deposition under a range of load conditions and fuel property variability in real time.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2026

Wireless High-Temperature Sensor Network for smart boiler systems

This final project report describes the research data and findings. This project aims to develop a new wireless high-temperature sensor network for real-time continuous boiler condition monitoring in harsh environments. Such a wireless high-temperature sensor network enables network-based automatic temperature sensing and data collection, which combined with artificial intelligent (AI) algorithms allow the construction of smart boiler systems with boiling condition management and optimization for significant energy-saving and reliability improvement

42 ENGINEERING↗
DOE OSTI2023

Modular Staged Pressurized Oxy-Combustion (SPOC) Power Plant for Coal and Biomass – Integration of Combustor Boiler and DCC

Critical to the future of power generation is the development of a power plant that will be capable of flexible operation to meet the needs of the modern grid, providing resilient, low-emissions power to a grid that is increasingly seeing a large penetration of intermittent wind and solar. The modular Staged, Pressurized Oxy-Combustion (SPOC) process envisioned by and under development at Washington University in St. Louis (WUSTL) has the potential to achieve these goals. The process offers: 1) a modular plant design for improved operational flexibility; 2) fuel-staging combined with pressurized oxy-combustion, which leads to smaller plant size, higher plant efficiency, and lower cost for pollutant and greenhouse gas removal compared with traditional carbon-capture equipped coal power plants; and 3) small modular boilers and pollutant removal units that can be fabricated in shop and assembled on site, further reducing plant capital costs. Under DOE's support (DE-FE0031925), WUSTL is advancing the development of the critical components for the SPOC power plant, including the integrated combustion system and the direct contact cooler (DCC) from Technology Readiness Level (TRL) 4 to TRL-5, which would allow these technologies to be subsequently incorporated into a pilot plant. This talk will present an overview of the SPOC technology, CFD modeling and validation for burner and boiler development, and recent results to evaluate critical components for system integration needed to advance its TRL.

Magalhaes, Duarte↗
DOE OSTI2026

Robust Heat-Flux Sensors for Coal-Fired Boiler Extreme Environments

In this project, robust heat-flux measurement systems were developed. The heat-flux sensors utilize thermoelectric effects to directly transduce the heat-flux inputs to analog electrical voltage signals. They were constructed from dedicated materials that can withstand temperatures of at least 1000°C and maintain adequate performance at these conditions for prolonged periods of time. The proposed approaches took into account numerous considerations, including system cost, sensor head resilience, sensor footprint, data accuracy, response time, and maintenance requirements. Through modern thermoelectric materials design, methodical materials selection and rigorous testing in materials characterization labs and medium-scale fire research facilities, we have demonstrated functioning laboratory prototypes, upon which one could base industrial heat-flux sensing platforms capable of operating in the challenging high-temperature, corrosive environments of the boilers of coal-fired power plants. A distributed sensor array for heat-flux measurements throughout the furnace water-wall, the superheater area and the economizer coils can provide critical data for the power plant control systems to increase efficiency, improve safety and reduce down times. For example, the combined heat-flux sensor/control systems can contribute to the optimization of burner and boiler operations under flexible loads, the optimization of heat-exchange conditions and overall reduction of heat rate and emissions, the prediction of imminent overheating conditions, and the optimization of the soot-blowing protocols.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2020

Radiant boiler for pressurized oxy-combustion and method of radiant trapping to control heat flux in high temperature particle-laden flows at elevated pressure

A boiler has a shell surrounding a vertical centerline. The shell defines an inner surface having an inner diameter and an inner length extending between an upper upstream end and a lower downstream end. The inner surface defines a hollow interior, the boiler having a pre-combustion zone, a combustion zone downstream from the pre-combustion zone, and a post-combustion zone downstream from the combustion zone. The shell is tapered outward along its length in at least a portion of the combustion zone. An oxidizer inlet is in fluid communication with the pre-combustion zone, and a fuel nozzle introduces fuel into the combustion zone. A tube assembly is mounted in the hollow interior of the shell for transferring heat to fluid flowing through the tube assembly. A flue duct is in fluid communication with the post-combustion zone for transporting flue gases from the hollow interior.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2021

Draft ASME Boiler and Pressure Vessel Code Cases and Technical Bases for Use of Alloy 617 for Constructions of Nuclear Component Under Section III, Division 5

The American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code currently only allows five materials for use in construction of nuclear components for high temperature service. These are: 2.25Cr-1Mo and V-modified 9Cr-1Mo steels, Types 304 and 316 stainless steels and the high nickel Alloy 800H. Since 2005, the US high temperature gas-cooled reactor program has been characterizing elevated temperature mechanical properties of Alloy 617 as the leading candidate construction material for the intermediate heat exchanger. After analysis of these experimental results, along with historical data and additional results available through the Generation IV International Forum, Very High Temperature Reactor, Materials Program Management Board Materials Handbook, a draft ASME Code Case to allow nuclear construction with Alloy 617 for temperatures up to 1750°F (954°C) has been developed. This report contains the Code Case for Low Temperature Service Construction of Section III, Division 5, Subsection HB, Subpart A, Class A and Subsection HC, Subpart A, Class B components, which has been approved in Section II, Materials, and Section III, Rules for Construction of Nuclear Facility Components. Supporting technical justification for the low temperature Code Case is also included. This Code Case allows use of Alloy 617 up to 800°F (425°C). This report also contains an updated draft of a Section III, Division 5, Subsection HB, Subpart B, Class A Code Case for Alloy 617 to qualify it for use in construction of nuclear components up to 1750°F (954°C) for service life up to 100,000 hours. The draft contained in Appendix 4, subject to editorial revision and approval by the ASME Special Task Group on Alloy 617 Code Qualification, will be submitted for approval by letter ballot by the appropriate ASME Committees. The technical justification supporting the Code Case is presented in Appendix 5 of this report. This background document is part of the information package that will be submitted with the Code Case for ballot.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Plasma Ignition and Combustion Stabilization Technology to Improve Flexible Operation, Reliability and Economics of an Existing Coal-Fired Boiler

GE Steam Power, Inc. (GE) proposed to improve reliability, flexibility, and economics of an existing coal-fired power plant by applying a new advanced technology developed by GE, a plasma-assisted pulverized fuel firing system. The objective of this program is to demonstrate the achievement of lower load by improved flame stabilization and therefore lower operating costs in a full-scale field installation at coal-fired electric utility. GE’s Plasma Ignition and Combustion Stabilization System is designed to operate continuously to support low load operation. With the plasma on, the flame will be attached and stable, removing the firing system as a limitation to low load operation. In addition, GE’s exclusively from ABENZ company licensed AC based technology has a 90+% system efficiency compared to all other systems at which are DC and operate with ~75% efficiency. Plant operating costs are lowered by eliminating use of expensive support fuel as well as the ability to operate at lower loads. The utilities’ ability to better match the demand curve will result in significant savings. Maintenance is lower for an AC system than a DC system as it operates at lower current. This eliminates the need for a demineralized cooling water system and provides longer electrode life which translates into both material and labor savings. It is the objective of GE to not only demonstrate the additional low load achievable with a plasma system after best achievable tuning, sensor and software approach has been exhausted, but also the increased stability of the flame at all loads with plasma assistance as well as cost savings at all low loads using plasma instead of oil. Upon successful completion of this project, GE will have sufficient field experience to rapidly deploy the Plasma Technology. The project objectives were achieved through the implementation of plasma ignitor technology at PacifiCorp Hunter Station Unit 3. A plasma ignitor system was retrofitted on ten wall-fired burners, Mill 3-4 combustion system. The Plasma Ignitors installed at Hunter proved that this GE technology is a direct and complete replacement for the original oil ignitors. The Hunter Unit 3 burner management system allows the plasma system to be used in all applications that originally required oil to be burned. This includes any time the Mill 3-4 is started or stopped for any reason including boiler starts, load changes, and low load support.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2021

RIC Advanced Sensors & Controls FWP: Novel Sensors for Boilers

Overview and brief project update on 3 tasks within the RIC Advanced Sensors & Controls FWP with direct applications to coal fired boiler temperature sensing. Task 32, Field demonstration of distributed temperature measurement with optical fiber for fossil energy power generation applications. Task 47, In-situ temperature measurements via reactive particles. Task 48, Ultrafast laser measurements for power generation environments.

coal boilers↗
DOE OSTI2025

Boiler Health Monitoring Using a Hybrid First Principles-Artificial Intelligence Model

Due to increased penetration of the intermittent renewables to the grid, pulverized coal (PC) plants are being forced to cycle their load frequently and rapidly, operate at low load condition for sustained period, and start up and shut down several hundred times in a year in the worst case. These severe operations are causing substantial damage to the boiler components compromising the reliability of PC plants. An online health monitoring tool can be instrumental in understanding the impacts of load-following and can eventually help PC plants to develop advanced process control strategies for improved flexibility without compromising safety nor reliability.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2020

Data analytics for leak detection in a subcritical boiler

For decades, boiler leaks have been the leading cause of forced outages in the coal-fired unit. The leak occurrences are currently escalating since the existing plants must satisfy faster-ramping rates to support grid operation. Data analytics including Principal Component Analysis, Canonical Variate, and Fisher Discriminant Analysis were combined for detecting and characterizing the leak in a commercial 650 MW subcritical coal-fired power plant. The combined approach was shown to be highly effective in the fault investigation that would not have been easily achieved by an individual technique. The variability in both training and validation datasets was first evaluated using PCA. Then, the CV-FDA was employed to discriminate among faults, and to categorize the processed data into two main groups: no-leak (0) and leak (1), providing the timeframe and location of the leak occurrence. Furthermore, about 8,014 observations from 81 process variables were initially included in the calculation, while the variable count was reduced to 4 with less than 1% misclassification rate in total observations. Finally, the leak was isolated in the waterwall section. Thus, the outcome of this research may provide early detection and isolation of faulty operations in the coal-fired power plant that involves a considerable number of process variables.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2022

Dynamic machine learning-based optimization algorithm to improve boiler efficiency

With decreasing computational costs, improvement in algorithms, and the aggregation of large industrial and commercial datasets, machine learning is becoming a ubiquitous tool for process and business innovations. Machine learning is still lacking applications in the field of dynamic optimization for real-time control. This work presents a novel framework for performing constrained dynamic optimization using a recurrent neural network model combined with a metaheuristic optimizer. The framework is designed to augment an existing control system and is purely data-driven, like most industrial Model Predictive Control applications. Several recurrent neural network models are compared as well as several metaheuristic optimizers. Hyperparameters and optimizer parameters are tuned with parameter sweeps, and the resulting values are reported. Further, the best parameters for each optimizer and model combination are demonstrated in closed-loop control of a dynamic simulation, and several recommendations are made for generalizing this framework to other systems. Up to 0.953% improvement is realized over the non-optimized case for a simulated coal-fired boiler. While this is not a large improvement in percentage, the total economic impact is $991,000 per year, and this study builds a foundation for future machine learning with dynamic optimization.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Application of the ASME Boiler and Pressure Vessel Code in the Design of SRF Cavities at Fermilab

Jacketed Superconducting Radio Frequency (SRF) cavities structurally comprise of an inner niobium vessel surrounded by a liquid helium containment vessels. The pressure of the helium bath and/or its volume might be such that a jacketed SRF cavity shall be considered a system of pressure vessels. Thus, methods described in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code (BPVC) should be used to analyze the structural soundness of jacketed SRF cavities. This paper will report the use of the set of rules developed at Fermilab for the design of SRF cavities, such as jacketed 1.3 GHz cavities for LCLS-II HE and jacketed Single Spoke Resonator type~2 (SSR2) for PIP-II, to ensure a similar level of safety as prescribed by the ASME BPVC.

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

Damage Accumulations Predictions for Boiler Components Via Microstructurally Informed Material Models

The goal of the project was to model material behavior and degradation during cyclic plasticity— with and without hold time—for nickel-based superalloys used in USC (ultra-super-critical) and A-USC (advanced-ultra-super-critical) boiler components. The study provided physically informed models, capturing the microstructural changes taking place in the industrial components under cyclic loading and long duration stress (up to 300,000 hours) and high temperature exposure (1100°F/593°C to 1400°F/760°C). The major developments were: 1) Qualitative and quantitative understanding of microstructure evolution (gamma prime precipitates), deformation (dislocation density), and damage mechanisms of Haynes ® 282 alloy. 2) Qualitative understanding of microstructural features generating local strain variations. 3) A continuum damage mechanics model (CDM) for Haynes ® 282 alloy at 1100°F to 1400°F capturing cyclic behavior with and without hold time. 4) Structural analysis for creep and LCF life predictions of an USC thick-wall Grade 91 superheater steel header and understanding life sensitivity to wall thickness of an AUSC Haynes ® 282 header.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2024

End-Use Savings Shapes Upgrade Package Documentation: LED Lighting, HP-RTU and ASHP-Boiler

Building on the successfully completed effort to calibrate and validate the U.S. Department of Energy's ResStock and ComStock models over the past 3 years, the objective of this work is to produce national data sets that empower analysts working for federal, state, utility, city, and manufacturer stakeholders to answer a broad range of analysis questions. The goal of this work is to develop energy efficiency, electrification, and demand flexibility end-use load shapes (electricity, gas, propane, or fuel oil) that cover a majority of the high-impact, market-ready (or nearly market-ready) upgrade measures, or upgrades. "Measures" refers to energy efficiency variables that can be applied to buildings during modeling. An end-use savings shape is the difference in energy consumption between a baseline building and a building with an energy efficiency, electrification, or demand flexibility upgrade applied. It results in a time-series profile that is broken down by end use and fuel (electricity or on-site gas, propane, or fuel oil use) at each time step. ComStock is a highly granular, bottom-up model that uses multiple data sources, statistical sampling methods, and advanced building energy simulations to estimate the annual subhourly energy consumption of the commercial building stock across the United States. The baseline model intends to represent the U.S. commercial building stock as it existed in 2018. The methodology and results of the baseline model are discussed in the final technical report of the End-Use Load Profiles project. This documentation focuses on an upgrade package of three end-use savings shapes upgrades - Light Emitting Diode (LED) Lighting, Heat Pump Rooftop Unit (RTU) (HP-RTU), and Air-Source Heat Pump (ASHP) Boiler, which we will refer to collectively as the "Interior Lighting and Heat Pump" package. More details on the individual upgrades can be found on the ComStock Measures Documentation page. An upgrade package applies two or more EUSS upgrades to a single building model simulation. Since ComStock is a bottom-up physics-based model, an upgrade package will go beyond aggregating or summing the individual upgrade results and produce novel results by simulating interactions between the upgrades. For example, pairing an envelope upgrade with an electrification upgrade would likely result in higher savings results than the sum of these upgrades individually, and the size of the heating, ventilating, and air conditioning (HVAC) equipment may be reduced if the envelope upgrade reduces the loads significantly.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗