Superalloy by powder metallurgy for use at 1000-1400 F Final report
Argon atomized nickel alloys processed thermochemically for use at high temperatures
Kotval, P. S.↗
SEARCH · Engineering Papers
Results for “thermochemical processing”
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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The Conceptual Design of an Integrated Nuclearhydrogen Production Plant Using the Sulfur Cycle Water Decomposition System
A hydrogen production plant was designed based on a hybrid electrolytic-thermochemical process for decomposing water. The sulfur cycle water decomposition system is driven by a very high temperature nuclear reactor that provides 1,283 K helium working gas. The plant is sized to approximately ten million standard cubic meters per day of electrolytically pure hydrogen and has an overall thermal efficiently of 45.2 percent. The economics of the plant were evaluated using ground rules which include a 1974 cost basis without escalation, financing structure and other economic factors. Taking into account capital, operation, maintenance and nuclear fuel cycle costs, the cost of product hydrogen was calculated at $5.96/std cu m for utility financing. These values are significantly lower than hydrogen costs from conventional water electrolysis plants and competitive with hydrogen from coal gasification plants.
Farbman, G. H.↗
Thermochemical-photolytic production of H2 and O2 from water
Low-temperature closed-cycle reactions are used to effect decomposition of water through multistep thermochemical process.
Krascella, N. L.↗
Prediction of nearfield jet entrainment by an interactive mixing/afterburning model
The development of a computational model (BOAT) for calculating nearfield jet entrainment, and its application to the prediction of nozzle boattail pressures, is discussed. BOAT accounts for the detailed turbulence and thermochemical processes occurring in the nearfield shear layers of jet engine (and rocket) exhaust plumes while interfacing with the inviscid exhaust and external flowfield regions in an overlaid, interactive manner. The ability of the model to analyze simple free shear flows is assessed by detailed comparisons with fundamental laboratory data. The overlaid methodology and the entrainment correction employed to yield the effective plume boundary conditions are assessed via application of BOAT in conjunction with the codes comprising the NASA/LRC patched viscous/inviscid model for determining nozzle boattail drag for subsonic/transonic external flows. Comparisons between the predictions and data on underexpanded laboratory cold air jets are presented.
Dash, S. M.↗
A computational model for the prediction of jet entrainment in the vicinity of nozzle boattails (the BOAT code)
The development of a computational model (BOAT) for calculating nearfield jet entrainment, and its incorporation in an existing methodology for the prediction of nozzle boattail pressures, is discussed. The model accounts for the detailed turbulence and thermochemical processes occurring in the mixing layer formed between a jet exhaust and surrounding external stream while interfacing with the inviscid exhaust and external flowfield regions in an overlaid, interactive manner. The ability of the BOAT model to analyze simple free shear flows is assessed by comparisons with fundamental laboratory data. The overlaid procedure for incorporating variable pressures into BOAT and the entrainment correction employed to yield an effective plume boundary for the inviscid external flow are demonstrated. This is accomplished via application of BOAT in conjunction with the codes comprising the NASA/LRC patched viscous/inviscid methodology for determining nozzle boattail drag for subsonic/transonic external flows.
Dash, S. M.↗
High atmospheric NO(x) levels and multiple photochemical steady states
The rate of removal of atmospheric NO(x) compounds at different NO(x) levels is estimated using a one-dimensional photochemical model. NO(x) removal by wet deposition, surface deposition, and thermochemical processes is examined. NO(x) removal rates at different surface NO mixing ratios are calculated and the data are analyzed. It is revealed that at low NO(x) levels NO(x) is photochemically converted to HNO3 by either wet or dry deposition; however, at high NO(x) levels formation of HNO3 is inhibited due to the disappearance of tropospheric ozone and OH, and the NO(x) is removed by rainout of N2O4 and N2O5, surface deposition of NO and NO2, and direct dissolution of NO and NO2 in rainwater. The effects of NO(x) mixing ratios greater than 10 to the -7th on the ozone and climate are investigated.
Kasting, J. F.↗
Review of a code development and calibration program in support of the aeroassist flight experiment
The code development and calibration program for the Langley Aerothermodynamic Upwind Relaxation Algorithm (LAURA) is reviewed, with emphasis directed toward support of the Aeroassist Flight Experiment (AFE). The flight project is designed to obtain data which will be used in the validation of computational fluid dynamic approximation methods. Comparisons between experimental data and numerical simulation focus on perfect-gas tests over a scale model of the AFE and on flight and ground tests which challenge some aspect of the thermochemical nonequilibrium model. In the first case, the gas model is simple, but the grid-related problems of defining the real vehicle are present. In the second case, the vehicle geometries are simple, but thermochemical processes must be modeled correctly in order to compare with the experimental data. These comparisons are described as calibration runs because they test elements of the numerical simulation, but no single data set adequately simulates the full-scale AFE flight conditions. Comparisons between computation and experiment over a broad range of data sets show generally good agreement, though some aspects of the numerical model require further development.
Gnoffo, Peter A.↗
Development and application of computational aerothermodynamics flowfield computer codes
Research was performed in the area of computational modeling and application of hypersonic, high-enthalpy, thermo-chemical nonequilibrium flow (Aerothermodynamics) problems. A number of computational fluid dynamic (CFD) codes were developed and applied to simulate high altitude rocket-plume, the Aeroassist Flight Experiment (AFE), hypersonic base flow for planetary probes, the single expansion ramp model (SERN) connected with the National Aerospace Plane, hypersonic drag devices, hypersonic ramp flows, ballistic range models, shock tunnel facility nozzles, transient and steady flows in the shock tunnel facility, arc-jet flows, thermochemical nonequilibrium flows around simple and complex bodies, axisymmetric ionized flows of interest to re-entry, unsteady shock induced combustion phenomena, high enthalpy pulsed facility simulations, and unsteady shock boundary layer interactions in shock tunnels. Computational modeling involved developing appropriate numerical schemes for the flows on interest and developing, applying, and validating appropriate thermochemical processes. As part of improving the accuracy of the numerical predictions, adaptive grid algorithms were explored, and a user-friendly, self-adaptive code (SAGE) was developed. Aerothermodynamic flows of interest included energy transfer due to strong radiation, and a significant level of effort was spent in developing computational codes for calculating radiation and radiation modeling. In addition, computational tools were developed and applied to predict the radiative heat flux and spectra that reach the model surface.
Venkatapathy, Ethiraj↗
Modeling of hypersonic reacting flows
The effect of nonequilibrium thermochemical processes on the aerodynamic and heat transfer characteristics of a hypersonic vehicle is illustrated with examples. It is shown that the conventional method of predicting chemical reactions always predict that the flow is closer to equilibrium than it actually is, leading to incorrect predictions of aerodynamic characteristics of a vehicle. A method is presented for predicting chemical processes using a two-temperature kinetic model, which is developed on the basis of combining conservation equations for vibrational energy and for electron electronic energy, which are also derived. The validity of the two-temperature model is proven using two types of experimental data: radiation and shock shapes.
Park, Chul↗
Technoeconomic Analysis of a Solar Thermochemical Fuel Production Process Using a Packed-Bed Redox Reactor
The production of sustainable liquid fuels is paramount in decarbonization of difficult to abate sectors such as the aviation and maritime sectors. Solar thermochemical fuel production is a promising pathway to produce such fuels using concentrated solar thermal (CST) power driving high-temperature redox reactions, coupled with a gas-to-liquid process. In this work we present a preliminary technoeconomic analysis of a solar fuels plant, utilizing a new fixed-bed countercurrent redox reactor and combining both CST and photovoltaic arrays to supply the required energy.
ENERGY STORAGE,HYDROGEN,SOLAR ENERGY↗
Development of a Techno-Economic Analysis Framework for a Solar Thermochemical Fuel Production Process
Synthetic liquid fuels can provide a drop-in substitute for fossil-based fuels in sectors such as aviation and maritime, where electrification is not a viable option due to the need for high specific energy density. However, for these alternative fuels to be adopted at a commercial scale, their price must be competitive compared to their fossil-based counterparts. The reverse water-gas shift (RWGS) reaction offers a promising pathway, using hydrogen (sourced from electrolysis) and carbon dioxide as the feed and reacting to produce syngas - a mixture of H2 and CO at a specific ratio. Syngas is a useful precursor that can be converted into fuels and chemicals via known downstream processes, such as liquid transportation fuels via Fischer-Tropsch (FT) synthesis. The RWGS reaction is currently not applied in commercial scale, unlike the rest of the components in the process chain (electrolyzers and syngas-to-fuel synthesis units). The RWGS reaction poses several challenges due to its restrictive thermodynamics. Being an equimolar reaction, high temperatures and a large excess of H2 are needed to achieve reasonable CO2 conversion at equilibrium. This has detrimental effects on practical process implementation and the quality of syngas that can be produced, with direct effect on the energy and capital requirements, as well as the need for expensive downstream separation. In this work, we are proposing to develop a new concentrating solar thermal (CST) compatible RWGS reactor, performing the reaction in a 2-step chemical looping process using metal oxide at a temperature range of 600-800 degrees Celsius. By decoupling the reactor from the solar receiver, the Generation 3 (Gen3) CST technology could be utilized, together with its proposed thermal energy storage (TES) technology, benefitting from a good match to the required temperatures. CST technology is a viable option for supplying the heat that could be rapidly deployed in scale, thus being a good match to the gas-to-liquid (GTL) process which requires a large minimal scale to be commercially viable. The integration of TES with CST also allows operating the plant at large annual capacity factors and avoids multiple shutdown/startup cycles, thus fitting into the steady-state operation mode that most GTL processes require. The main innovation in the proposed design hinges on a countercurrent reaction design using a packed bed reactor. In 2019 Metcalfe et al. showed the benefits of countercurrent species exchange could be realized in a redox chemical-looping processes, by storing the favorable countercurrent chemical potential profiles in a packed bed of non-stoichiometric oxide. Metcalfe et al. applied this breakthrough concept to the WGS reaction, which is conventionally a co-feed catalytic process, showing a dramatic improvement. Bulfin et al. (2023) performed a similar proof-of-concept demonstration for the RWGS reaction using CeO2, achieving cumulative and peak CO2 conversions of 88% and 95%, respectively, compared to a thermodynamic limit of 58% for the co-feed catalytic process at the same conditions. In our new REGENLOOP project, we are developing a reactor prototype from the heat-exchange packed bed reactor-type, a commonly used reactor in the chemical industry. The endothermic heat of reduction will be supplied to the reactor using CST, while the same heat transfer fluid (HTF) mechanism will be used to extract the exothermic heat of oxidation. An array of multiple reactors is used to supply constant high-purity CO stream, that is then mixed with H2 from electrolysis to produce a high-purity syngas at the required composition. By removing the CO-CO2 separation after the RWGS process, significant energy and cost reduction can be achieved. A physics-based TEA framework is currently being developed, covering all the major plant processes, from the solar collection through storage, chemical looping RWGS, GTL, and auxiliary unit operations, up to the liquid hydrocarbon product. This modeling framework will utilize reduced-order models for the chemical looping RWGS and TES, CST modeling using SolarPILOT, and Aspen Plus for the GTL. By using this combined physics-based approach, the effects of design/operating parameters on the performance and cost can be elucidated. In our presentation, the modeling framework will be presented in detail, including preliminary cost predictions of using this plant configuration under a few selected relevant case studies. This study will be used to identify the major cost drivers, informing further system design and optimization needed to chart the way for a commercially viable pathway.
14 SOLAR ENERGY↗
Opportunities and challenges in thermochemical conversion of municipal solid waste: A comprehensive review
Recent advancements in thermochemical conversion processes have elucidated new pathways for converting municipal solid waste into valuable resources. This review explores the primary thermochemical conversion methods, including combustion, gasification, pyrolysis, torrefaction, hydrothermal carbonization, and hydrothermal liquefaction, emphasizing their potential roles in waste management and energy recovery. Key challenges including feedstock variability, ash behavior, and scale-up limitations are discussed alongside opportunities for hybrid systems and circular economy integration. A comparative analysis of research publications indicates a significant focus on thermochemical pathways within the broader context of municipal solid waste research, underscoring the growing interest in these technologies. Recent advancements in each thermochemical process, alongside their operational, technical, and economic challenges, are discussed. Comparative data reveal that torrefaction enhances the hydrophobicity and grindability of municipal solid waste components, though its energy densification benefits are more modest than those observed in biomass. Hydrothermal carbonization and liquefaction are highlighted for their ability to process high-moisture and heterogeneous waste streams. The review also synthesizes recent findings on reactor configurations, emissions control, and synergistic effects in co-processing municipal solid waste fractions. The findings underscore the importance of developing standardized protocols for municipal solid waste characterization and the need for innovative hybrid systems to improve efficiency.
99 - GENERAL AND MISCELLANEOUS↗
Comparative Life Cycle Assessment of Bacterial and Thermochemical Retting of Hemp
The processes of hemp bast fiber retting, forming, and drying offer the opportunity for value-added products such as natural fiber-reinforced composites. A new process for the retting of raw bast fibers through enzyme-triggered self-cultured bacterial retting was developed in the lab-scale setup. This study focused on comparing the energy consumption and environmental impacts of this bacterial retting process with the thermochemical retting process currently widely used to obtain lignocellulosic fibers for composites. The gate-to-gate life cycle assessment (LCA) models of the two retting processes were constructed to run a comparison analysis using the TRACI (the tool for the reduction and assessment of chemical and other environmental impacts) method for environmental impacts and the cumulative energy demand (CED) method for energy consumptions. This work has demonstrated the advantages of the bacterial retting method from an environmental standpoint. The result of our research shows about a 24% gate-to-gate reduction in CED for bacterial retting and 20–25% lower environmental impacts relating to global warming, smog formation, acidification, carcinogenics, non-carcinogenics, respiratory effects, ecotoxicity, and fossil fuel depletion when compared to that of thermochemical retting.
Chemistry↗
Thermochemical analysis of chemical processes relevant to the stability and processing of SiC-reinforced Si3N4 composite
Chemical processes relevant to the stability and processing of SiC-reinforced Si3N4 composites have been examined from thermochemical considerations. The thermodynamic stabilities of various interfaces, such as SiC-Si3N4, SiC-Si3N4-Si2ON2, and SiC-Si3N4-SiO2, have been examined as a function of temperature, and the temperatures above which these interfaces become unstable have been calculated. The degradation of SiC during the processing of the composite has been examined. The processing routes considered in this study include the reaction bonded silicon nitride (RBSN) process and the pressure-assisted sintering processes with suitable sintering additives.
Misra, Ajay K.↗
Electrochemical Cycling of Liquid Organic Hydrogen Carriers as a Sustainable Approach for Hydrogen Storage and Transportation
Hydrogen (H 2 ), as a high-energy-density molecule, offers a clean solution to carry energy. However, the high diffusivity and low volumetric density of H 2 pose a challenge for long-term storage and transportation. Liquid organic hydrogen carriers (LOHCs) have been suggested as a strategic way to store and transport hydrogen in stable molecules. More so, electrochemical LOHC cycling renders an opportunity to utilize renewable energy for hydrogen storage and transportation toward the goal of eliminating carbon emissions. In this Perspective, examples of electrochemical reactions of organic molecules and their suitability for LOHC couples are examined. A comparative carbon footprint assessment of electrochemical LOHC cycling processes against thermochemical and hybrid LOHC cycling processes was performed. The electrochemical LOHC cycling process had the lowest relative carbon footprint only when highly concentrated LOHCs were used as the feed or when purification of the LOHC product was not required. The carbon footprint in electrochemical cycling of diluted LOHC was primarily contributed to by the LOHC distillation separation process. A sensitivity analysis showed the carbon footprint LOHC concentration dependence during the electrochemical cycling process. Moreover, the electrolyte composition significantly affects the carbon footprint during electrochemical LOHC cycling. Energy utilization, water usage, and toxicity for electrochemical LOHC cycling are discussed to provide an overview for better economic and environmental practices. There are significant opportunities in the electrochemical cycling of LOHCs if appropriate conditions such as high concentrations of reactant, reversible redox cycling ability, high Faradaic efficiencies, and catalyst stabilities are achieved.
25 ENERGY STORAGE↗
Science of Scale-Up: Accelerating chemical manufacturing technology development workshop report
The Science of Scale-Up: Accelerating chemical manufacturing technology development workshop report outlines key insights and actionable recommendations for accelerating the scale-up of disruptive chemical manufacturing technologies. Convened in October 2024, the workshop brought together approximately fifty experts from academia, industry, national laboratories, and government agencies to address the barriers and solutions for maturing technologies from proof-of-concept to commercialization. The report identifies seven critical themes for enabling faster scale-up. These themes were explored through general discussions and breakout sessions focused on three specific chemical manufacturing technologies—electrochemical, thermochemical, and biological conversion processes. The findings emphasize the importance of interdisciplinary collaboration, robust funding mechanisms, and shared resources to overcome technical barriers and accelerate technology deployment. The report also highlights technology-specific challenges and opportunities, including the need for advanced materials, scalable manufacturing processes, and integrated testing environments. For electrochemical manufacturing processes, durability and material optimization are key priorities, while thermochemical processes require novel reactor designs and better supply chain integration. Biological conversion processes face hurdles in strain engineering, reactor design, and process integration. Across all technologies, the workshop emphasized the importance of leveraging computational tools, standardized protocols, and collaborative networks to address knowledge gaps and technical barriers. By acting on these insights, stakeholders can reduce the timeline for scaling up critical chemical manufacturing technologies, ensuring their timely impact on manufacturing competitiveness, and environmental sustainability.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
R&D with NREL's Davison Circulating Riser System
The Davison circulating riser (DCR) is the National Renewable Energy Laboratory's (NREL's) pilot-scale recirculating riser reactor system. Coupled with an upstream fluid-bed pyrolysis system, it permits evaluation of catalytic cracking of biogenic feedstocks, as well as coprocessing of biogenic and fossil feedstocks in a commercially relevant pilot fluid catalytic cracker.
09 BIOMASS FUELS↗