Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “STEAM”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 541 records · Page 30
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Embedded sensors integrated into critical components for in situ health monitoring of steam turbines

Operational flexibility is desired in today’s coal-fired power plants to balance power grids by compensating for the variable electricity supply from renewable energy sources and distributed gensets. This demanding requirement accelerates materials degradation and makes in-situ health monitoring essential. Life monitoring of components and subsystems is thus seen as essential in assessing material and mechanical behavior to estimate system reliability, move to a conditionbased maintenance strategy and determine time to failure of the units in their actual operating conditions. Vibration monitoring can be exploited for blade tip timing to measure blade vibration amplitude and tip clearance to detect any deterioration taking place in the condition of steam turbine blades. A failure of a rotating blade can lead to severe turbine damage followed by extensive repairs and loss of power production. A blade vibration monitoring system can help early detection of abnormal blade vibration behavior. In conjunction with a health monitoring system, the vibration characteristics can be analyzed to support a pro-active maintenance and inspection schedule. While the feasibility of this inspection technique has been amply demonstrated, there is a need to install induction probes to magnetize the blade for signal output. Siemens, in partnership with Raytheon Technologies Research Corporation (RTRC), proposes a holistic approach to develop embedded sensors to utilize radio frequency for not only coupling to sensors, but as the sensing modality. The goal of this project is to “embed” the novel sensing approach by using either additively manufactured or extruded waveguides on rotating blades for recording, evaluation and monitoring of blade vibrations in Low Pressure turbines, with applications extending to aero engines

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2023

AOI 3 Life Modelling of Critical Steam Cycle Components in Coal-Fueled Power Plants

Microstructural damage accumulation models have been used to produce calibrated life estimation models for a DR22/P22 steel wye-block welds, and a Jethete stainless steel turbine blade (bucket). The calibrated life estimation models will aid the power plant operator in determining optimal maintenance and operation schedules based upon historical operational data as well as current, or future operation schemes. The impact of this project will enable existing coal-fueled power plants to operate safely for longer periods of time and at higher efficiencies, thereby reducing the economic and environmental impact of the existing coal power plant fleet. Testing, characterization, and modelling indicates that the operating life of P22 pipelines and their welds are dominated by fatigue damage mechanisms. Specifically, fatigue is of no concern in these materials when operating under realistic conditions manifesting in the main steam piping of coal-fueled power plants. However, if a low-temperature overload ever occurs during operation, fatigue will manifest as a damage mechanism of interest. Primary impact provided by the completion of this work is in the manifestation of a detailed ABAQUS solid model providing accurate boundary conditions to enable the prediction of operational stresses and strains. The completed plant solid model, in conjunction with the calibrated fatigue and creep life models provide definitive confirmation that creep is the dominant damage mechanism during operational conditions. Jethete life modelling has been completed by the manifestation of a material-specific, and temperature-specific, Kitagowa diagram. The Kitagowa diagram provides maintenance and operation decision making with scientifically-based go/no-go support based upon the crack-like features that have been identified by use of inspection.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2023

Parametric and Sensitivity Analysis of a Steam Generator Model Using Python and Machine-Learning Tools

For this study, we used Python and machine-learning tools to perform a comprehensive parametric and sensitivity analysis on a steam generator (SG) model. (The Python model was based on a previously completed MATLAB framework for the Holtec SMR-160 SG.) We investigated the influence of various input parameters (e.g., heat transfer coefficient [HTC], Nusselt number, and heat exchanger effectiveness) on the system’s output. With machine-learning tools such as the Risk Analysis Virtual Environment (RAVEN), which was developed at Idaho National Laboratory, we were then able to perform an automated analysis of the SG inputs’ effect on the HTC. The analysis results give valuable insights into the performance and optimization of SG systems. We found the inlet mass flow rate (MFR) to have the greatest impact on the HTC, followed closely by the inlet temperature, and then pressure. Shifting of the input parameters causes the location of the maximum HTC along the SG length to change incrementally. The cold leg (CL) MFR was also found to impact the HTC magnitude as well as the location of the maximum HTC. At between 0.4–0.9 of the total SG length, the input parameters experience maximum impact on the HTC, leading us to suggest that sensors be efficiently placed on the SG so as to closely and effectively monitor thermal-hydraulic properties during reactor operation. We also found that the sensitivity data calculated manually agrees with the RAVEN – based data, confirming the same range of maximum sensitivity. However, the RAVEN-based analysis showed that cold leg pressure and hot leg temperature have a greater impact on the heat transfer coefficient than the mass flow rate, implying that a manual sensitivity study taking only two samples is not accurate.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2013

Hydrogen Recovery and Carbon Dioxide Separation in Steam Methane Reformers (SBIR Phase II Final Report)

Approximately six trillion standard cubic feet (scf) of hydrogen are produced each year by steam reforming light hydrocarbons. The water gas shift portion of the process yields a hydrogen product containing significant quantities of by-products such as carbon dioxide. The hydrogen must be purified for further use and carbon dioxide, a primary global warming agent, should be captured for other applications or sequestration. Pressure swing adsorption (PSA) is often used to produce high-purity hydrogen. However, the tail gas coming out of PSA contains about 15% of the hydrogen produced from reforming, and is currently used as fuel for reformers. The overall goal of this DOE-funded SBIR project was to develop a membrane process to recover hydrogen from PSA tail gas. This process also produces liquid carbon dioxide for sequestration. In the Phase I project, polyamide polyether based membranes were developed and evaluated with pure gases and model mixed hydrogen containing gases. Two bench scale modules were fabricated from these membranes, and evaluated with pure gases. These membranes and modules provided high carbon dioxide permeance and high carbon dioxide/hydrogen selectivity. In the Phase II project, a modified polyamide polyether based membrane, Polaris (TM), was successfully developed, and the membrane permeances were greatly improved. Bench scale modules prepared from this membrane were tested in the laboratory. Industrial scale 8-inch diameter modules were prepared and tested at BP's Pascagoula Gas Processing Plant. The modules were exposed to high-pressure natural gas for three months in a long-term integrity test. The promising results in the laboratory and field tests have generated great interest in using Polaris (TM) membranes for carbon dioxide/hydrogen separations. The membranes and processes developed in this project are in the early stage of commercialization. This work has already resulted in the sale of one commercial membrane unit for carbon dioxide removal and hydrogen purification.

02 PETROLEUM↗
DOE OSTI2026

Tuning Methanol Transformation Pathways for Sustainable Steam Reforming: Na-Promotion Effects on Ag/m-ZrO 2 Catalysts

This work investigates the influence of sodium promotion on Ag/m-ZrO 2 catalysts for methanol steam reforming (MSR), focusing on activity, selectivity, surface chemistry, and mechanistic pathways. Temperature programmed reduction (TPR), XANES/EXAFS, CO 2 TPD, DRIFTS, and temperature programmed surface reaction methods were combined with fixed bed MSR testing to develop an integrated structure–function understanding of Na-modified Ag-ZrO 2 interfaces. Na addition systematically increases surface basicity, stabilizes strongly basic O 2− sites, and weakens the ν(CH) vibrational mode of surface formate, thereby facilitating C–H bond scission and accelerating decarboxylation to CO 2 . At moderate promoter levels (0.5–1.0 wt.% Na), the catalysts show significantly enhanced CO 2 selectivity and increased conversion relative to unpromoted Ag/m-ZrO 2 , while CH 4 formation remains negligible. Excessive Na (≥1.8 wt.%) leads to slower formate decomposition, greater carbonate stabilization, and suppressed conversion, revealing a narrow optimum around 1 wt.% Na. Short-term stability testing demonstrates steady conversion and product selectivity for both unpromoted and Na-promoted catalysts, with the latter maintaining markedly higher CO 2 selectivity. Although Pt/YSZ retains far superior intrinsic activity at ~10× higher space velocity, Ag offers a cost-advantaged alternative where lower cost metals are desirable. Collectively, these findings show that Na promotion enables tunable MSR selectivity on Ag/m-ZrO 2 by directing formate decomposition toward the CO 2 -forming pathway.

CO2 selectivity↗
DOE OSTI2026

Methanol Steam Reforming on Ru/m-ZrO 2 : Sodium Promotion of the CO 2 -Forming Pathway

Sodium (Na) promotion of Ru/m-ZrO 2 was investigated to elucidate how an alkali modification tunes selectivity in methanol steam reforming (MSR). H 2 -TPR/XANES/EXAFS show that Na increases surface basicity and strengthens Ru–O interactions, shifting RuO x reduction and H 2 spillover to a higher temperature. DRIFTS reveals Na-induced red shifts of the formate ν(CH) band and changes in OCO vibrational splitting, consistent with weakening of the formate C–H bond and an altered binding geometry. CO 2 -TPD confirms a monotonic shift toward stronger basic sites with increasing Na concentrations. Under MSR conditions, Na selectively increases CO2 concentration at the expense of CO. At ~80% conversion and 325 °C, CO 2 selectivity increases from 12.0% (unpromoted) to 16.2, 21.0, and 26.5% for 0.5, 1.0, and 1.8% Na, respectively; at ~300 °C and ~66–69% conversion, CO 2 selectivity increases from 8.6% to 23.7% at 1.8% Na. Transient MSR experiments further show earlier and larger H 2 evolution upon Na addition, corroborating the promotion of the dehydrogenation/decarbonylation route to CO 2 + H 2 . We propose that Na increases basicity and modifies the Ru–support interface to favor formate dehydrogenation/decarboxylation, thereby increasing the H 2 yield and lowering CO formation. Ru’s higher-energy, less occupied d-band stabilizes CO and oxygenated intermediates more strongly in the reforming environment, making the CO-forming pathway more resistant to suppression than on Pt.

CO2 selectivity↗
DOE OSTI2016

Integration of Methane Steam Reforming and Water Gas Shift Reaction in a Pd/Au/Pd-Based Catalytic Membrane Reactor for Process Intensification

Palladium-based catalytic membrane reactors (CMRs) effectively remove H2 to induce higher conversions in methane steam reforming (MSR) and water-gas-shift reactions (WGS). Within such a context, this work evaluates the technical performance of a novel CMR, which utilizes two catalysts in series, rather than one. In the process system under consideration, the first catalyst, confined within the shell side of the reactor, reforms methane with water yielding H2, CO and CO2. After reforming is completed, a second catalyst, positioned in series, reacts with CO and water through the WGS reaction yielding pure H2O, CO2 and H2. A tubular composite asymmetric Pd/Au/Pd membrane is situated throughout the reactor to continuously remove the produced H2 and induce higher methane and CO conversions while yielding ultrapure H2 and compressed CO2 ready for dehydration. Experimental results involving (i) a conventional packed bed reactor packed (PBR) for MSR, (ii) a PBR with five layers of two catalysts in series and (iii) a CMR with two layers of two catalysts in series are comparatively assessed and thoroughly characterized. Furthermore, a comprehensive 2D computational fluid dynamics (CFD) model was developed to explore further the features of the proposed configuration. The reaction was studied at different process intensification-relevant conditions, such as space velocities, temperatures, pressures and initial feed gas composition. Finally, it is demonstrated that the above CMR module, which was operated for 600 h, displays quite high H2 permeance and purity, high CH4 conversion levels and reduced CO yields.

water-gas-shift reaction↗
DOE OSTI2021

Promoting the Selectivity of Pt/m-ZrO 2 Ethanol Steam Reforming Catalysts with K and Rb Dopants

The ethanol steam reforming reaction (ESR) was investigated on unpromoted and potassium- and rubidium-promoted monoclinic zirconia-supported platinum (Pt/m-ZrO 2 ) catalysts. Evidence from in situ diffuse reflectance infrared Fourier transform spectroscopy (DRIFTS) characterization indicates that ethanol dissociates to ethoxy species, which undergo oxidative dehydrogenation to acetate followed by acetate decomposition. The acetate decomposition pathway depends on catalyst composition. The decarboxylation pathway tends to produce higher overall hydrogen selectivity and is the most favored route at high alkali loading (2.55 wt.% K and higher or 4.25 wt.% Rb and higher). On the other hand, decarbonylation is a significant route for the undoped catalyst or when a low alkali loading (e.g., 0.85% K or 0.93% Rb) is used, thus lowering the overall H 2 selectivity of the process. Results of in situ DRIFTS and the temperature-programmed reaction of ESR show that alkali doping promotes forward acetate decomposition while exposed metallic sites tend to facilitate decarbonylation. In previous work, 1.8 wt.% Na was found to hinder decarbonylation completely. Due to the fact that 1.8 wt.% Na is atomically equivalent to 3.1 wt.% K and 6.7 wt.% Rb, the results show that less K (2.55% K) or Rb (4.25% Rb) is needed to suppress decarbonylation; that is, more basic cations are more efficient promoters for improving the overall hydrogen selectivity of the ESR process.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS2013

Advanced Signal Processing for High Temperatures Health Monitoring of Condensed Water Height in Steam Pipes

An advanced signal processing methodology is being developed to monitor the height of condensed water thru the wall of a steel pipe while operating at temperatures as high as 250deg. Using existing techniques, previous study indicated that, when the water height is low or there is disturbance in the environment, the predicted water height may not be accurate. In recent years, the use of the autocorrelation and envelope techniques in the signal processing has been demonstrated to be a very useful tool for practical applications. In this paper, various signal processing techniques including the auto correlation, Hilbert transform, and the Shannon Energy Envelope methods were studied and implemented to determine the water height in the steam pipe. The results have shown that the developed method provides a good capability for monitoring the height in the regular conditions. An alternative solution for shallow water or no water conditions based on a developed hybrid method based on Hilbert transform (HT) with a high pass filter and using the optimized windowing technique is suggested. Further development of the reported methods would provide a powerful tool for the identification of the disturbances of water height inside the pipe.

health monitoring↗
NASA NTRS2013

High Temperatures Health Monitoring of the Condensed Water Height in Steam Pipe Systems

Ultrasonic probes were designed, fabricated and tested for high temperature health monitoring system. The goal of this work was to develop the health monitoring system that can determine the height level of the condensed water through the pipe wall at high temperature up to 250 deg while accounting for the effects of surface perturbation. Among different ultrasonic probe designs, 2.25 MHz probes with air backed configuration provide satisfactory results in terms of sensitivity, receiving reflections from the target through the pipe wall. A series of tests were performed using the air-backed probes under irregular conditions, such as surface perturbation and surface disturbance at elevated temperature, to qualify the developed ultrasonic system. The results demonstrate that the fabricated air-backed probes combined with advanced signal processing techniques offer the capability of health monitoring of steam pipe under various operating conditions.

High Temperatures (HT)↗
NASA NTRS2014

Wireless Monitoring of the Height of Condensed Water in Steam Pipes

A wireless health monitoring system has been developed for determining the height of water condensation in the steam pipes and the data acquisition is done remotely using a wireless network system. The developed system is designed to operate in the harsh environment encountered at manholes and the pipe high temperature of over 200 °C. The test method is an ultrasonic pulse-echo and the hardware includes a pulser, receiver and wireless modem for communication. Data acquisition and signal processing software were developed to determine the water height using adaptive signal processing and data communication that can be controlled while the hardware is installed in a manhole. A statistical decision-making tool is being developed based on the field test data to determine the height of in the condensed water under high noise conditions and other environmental factors.

High Temperatures↗
NASA NTRS2017

Flexural Fatigue Behavior of an EBC CMC Composite System In Air and Steam at High Temperature

Both coated and uncoated SiCSiC ceramic matrix composite (CMC) samples were tested in flexure under sustained peak low cycle fatigue (SPLCF) conditions in air or steam at elevated temperatures. The SiCSiC composites were reinforced with 2-D plies of boron nitride coated Hi-Nicalon Type-S SiC fibers which were woven as 5 harness satin (5HS) cloth. The composites were densified by chemical vapor infiltration (CVI) followed by slurry melt infiltration (SMI). A multilayer barium strontium aluminosilicate (BSAS) coating was applied to the samples by a plasma spray method. Fatigue loading limits were determined from monotonic flexure tests at room temperature and 1200oC. Stress levels under the proportional limit of the composite material were selected for the SPLCF tests. After cyclic testing, the composites were evaluated to determine crack propagation and failure modes in the coated and uncoated composites. Microstructural examination was used to identify coating degradation and failure modes of the EBCCMC system.

Steam testing↗