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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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627 records · Page 35
All sourcesNASA NTRSDOE OSTI
NASA NTRS1991

Analysis, design, and experimental results for lightweight space heat receiver canisters, phase 1

Critical technology experiments have been performed on thermal energy storage modules in support of the Brayton Advanced Heat Receiver program. The modules are wedge-shaped canisters designed to minimize the mechanical stresses that occur during the phase change of the lithium fluoride phase change material. Nickel foam inserts were used in some of the canisters to provide thermal conductivity enhancement and to distribute the void volume. Two canisters, one with a nickel foam insert, and one without, were thermally cycled in various orientations in a fluidized bed furnace. The only measurable impact of the nickel foam was seen when the back and short sides of the canister were insulated to simulate operation in the advanced receiver design. In tests with insulation, the furnace to back side delta T was larger in the canister with the nickel foam insert, probably due to the radiant absorptivity of the nickel. However, the differences in the temperature profiles of the two canisters were small, and in many cases the profiles matched fairly well. Computed Tomography (CT) was successfully used to nondestructively demarcate void locations in the canisters. Finally, canister dimensional stability, which was measured throughout the thermal cycling test program with an inspection fixture was satisfactory with a maximum change of 0.635 mm (0.025 in.).

Schneider, Michael G.↗
NASA NTRS1982

Application of the subatmospheric engine to solar thermal power

The development of a natural gas-fired Brayton engine is discussed. It is intended to be the prime mover for a 10-ton commercial heat pump. This engine has many attractive features that make it an ideal candidate for solar thermal-power generation applications. The unique feature of this engine is its subatmospheric mode of operation. It operates between atmospheric pressure and a partial vacuum. This means that heat is added to the cycle at atmospheric pressure; this permits the receiver to be unpressurized, greatly simplifying its design and cost.

Source record↗
NASA NTRS1986

Overview of NASA Lewis Research Center free-piston Stirling engine technology activities applicable to space power systems

Free piston Stirling technology is applicable for both solar and nuclear powered systems. As such, the Lewis Research Center serves as the project office to manage the newly initiated SP-100 Advanced Technology Program. This five year program provides the technology push for providing significant component and subsystem options for increased efficiency, reliability and survivability, and power output growth at reduced specific mass. One of the major elements of the program is the development of advanced power conversion concepts of which the Stirling cycle is a viable candidate. Under this program the research findings of the 25 kWe opposed piston Space Power Demonstrator Engine (SPDE) are presented. Included in the SPDE discussions are initial differences between predicted and experimental power outputs and power output influenced by variations in regenerators. Projections are made for future space power requirements over the next few decades. And a cursory comparison is presented showing the mass benefits that a Stirling system has over a Brayton system for the same peak temperature and output power.

Slaby, J. G.↗
NASA NTRS1981

Cost Analysis of an Air Brayton Receiver for a Solar Thermal Electric Power System in Selected Annual Production Volumes

Pioneer Engineering and Manufacturing Company estimated the cost of manufacturing and Air Brayton Receiver for a Solar Thermal Electric Power System as designed by the AiResearch Division of the Garrett Corporation. Production costs were estimated at annual volumes of 100; 1,000; 5,000; 10,000; 50,000; 100,000 and 1,000,000 units. These costs included direct labor, direct material and manufacturing burden. A make or buy analysis was made of each part of each volume. At high volumes special fabrication concepts were used to reduce operation cycle times. All costs were estimated at an assumed 100% plant capacity. Economic feasibility determined the level of production at which special concepts were to be introduced. Estimated costs were based on the economics of the last half of 1980. Tooling and capital equipment costs were estimated for ach volume. Infrastructure and personnel requirements were also estimated.

Source record↗
NASA NTRS1991

Space reactor/Stirling cycle systems for high power lunar application

An analysis is performed to mathematically model a 550 kWe lunar base power supply which uses a SP-100 reactor coupled with Stirling converters. The reactor is placed in an excavation to keep activated coolant in the hole and to allow maintenance of the components outside the hole. Two technology levels are considered. They are 1050 and 1300 K heater head Stirling converts. It is found that for a 1050 K converter the total mass which provided 1000 volts DC at 250 m is 14,366 kg while the 1300 K system mass is 12,104 kg. The radiation area of the 1050 and 1300 K systems are 641 and 356 sq m respectively. Comparisons are made with Brayton and thermionic systems with both near term and advanced technology considered.

Schmitz, Paul C.↗
NASA NTRS1991

Space reactor/Stirling cycle systems for high power lunar applications

An analysis is performed to mathematically model a 550 kWe lunar base power supply which uses a SP-100 reactor coupled with Stirling converters. The reactor is placed in an excavation to keep activated coolant in the hole and to allow maintance of the components outside the hole. Two technology levels are considered. They are 1050 and 1300 K heater head Stirling converts. It is found that for a 1050 K converter the total mass which provided 1000 volts dc at 250 m is 14,366 kg while the 1300 K system mass is 12,104 kg. The radiation area of the 1050 and 1300 K systems are 641 and 356 sq m respectively. Comparisons are made with Brayton and thermionic systems with both near term and advanced technology considered.

Schmitz, Paul C.↗
NASA NTRS2017

Hardware Assessment in Support of the Dynamic Power Convertor Development Effort

Stirling Radioisotope Power Systems (RPS) are being developed by NASA's RPS Program in collaboration with the U.S. Department of Energy (DOE). Efforts ranging from 2001 to 2015 enabled development of the Technology Demonstration Convertor (TDC) for use in the 110-watt Stirling Radioisotope Generator (SRG-110) and the Advanced Stirling Convertor (ASC) for use in the Advanced Stirling Radioisotope Generator (ASRG). The DOE selected Lockheed Martin Space Systems Company (LMSSC) as the system integration contractor for both flight development efforts. The SRG-110 housed two TDCs fabricated by Infinia and resulted in the production of 16x demonstration units and 2x engineering units. The project was redirected in 2006 to make use of a more efficient and lower mass ASCs under development by Sunpower Inc. The DOE managed the flight contract with LMSSC and subcontractor Sunpower Inc. from 2007 to 2013 to build the ASRG, with support from NASA Glenn Research Center (GRC). Sunpower Inc. held two parallel contracts to produce ASCs, one with Lockheed Martin to produce ASC-F flight units and one with GRC for the production of ASC-E3 engineering unit pathfinders that were used to refine the flight design and production processes. The DOE initiated termination of the ASRG contract in late 2013. After ASRG had ended, GRC completed characterization testing of the ASRG Engineering Unit #2 (EU2) and the GRC contract with Sunpower was also completed. The NASA RPS Program Office has recently initiated a new Dynamic Power Conversion development effort which includes the potential maturation of Stirling, Brayton, and Rankine power convertors for the next generation of RPS. The effort started with the request for proposal and review of submits. Contracts are anticipated for release in 2017 and will initially focus on a design phase prior to fabrication and testing. This new effort will focus on robustness in addition to high efficiency, specific power, and reliability. Also, some requirements introduced during the ASRG contract have also been included in the new effort, such as constant lateral loading. Due to the focus on robustness and new requirements relative to the older TDC design, the Stirling Cycle Development Project has initiated an assessment of government owned hardware to help inform requirements evolution and evaluation of future designs. While lessons learned from the ASRG flight development project have been taken into consideration, the evaluation of the TDC design had not been completed for some existing environments or relatively new requirements. To further assess the TDC design, a series of tasks were initiated to evaluate degradation for units that have operated unattended for over 105,000 hours, demonstrate robustness to a random vibration environment, characterize and evaluate performance for varying lateral load profiles. The status for each task are described.

Wilson, Scott D.↗
NASA NTRS2018

Hardware Assessment in Support of the Dynamic Power Convertor Development Effort

Stirling Radioisotope Power Systems (RPS) are being developed by NASAs RPS Program in collaboration with the U.S. Department of Energy (DOE). Efforts ranging from 2001 to 2015 enabled development of the Technology Demonstration Convertor (TDC) for use in the 110-watt Stirling Radioisotope Generator (SRG-110) and the Advanced Stirling Convertor (ASC) for use in the Advanced Stirling Radioisotope Generator (ASRG). The DOE selected Lockheed Martin Space Systems Company (LMSSC) as the system integration contractor for both flight development efforts. The SRG-110 housed two TDCs fabricated by Infinia and resulted in the production of 16x demonstration units and 2x engineering units. The project was redirected in 2006 to make use of a more efficient and lower mass ASCs under development by Sunpower Inc. The DOE managed the flight contract with LMSSC and subcontractor Sunpower Inc. from 2007 to 2013 to build the ASRG, with support from NASA Glenn Research Center (GRC). Sunpower Inc. held two parallel contracts to produce ASCs, one with Lockheed Martin to produce ASC-F flight units and one with GRC for the production of ASC-E3 engineering unit pathfinders that were used to refine the flight design and production processes. The DOE initiated termination of the ASRG contract in late 2013. After ASRG had ended, GRC completed characterization testing of the ASRG Engineering Unit 2 (EU2) and the GRC contract with Sunpower was also completed. The NASA RPS Program Office has recently initiated a new Dynamic Power Conversion development effort which includes the potential maturation of Stirling, Brayton, and Rankine power convertors for the next generation of RPS. The effort started with the request for proposal and review of submits. Contracts are anticipated for release in 2017 and will initially focus on a design phase prior to fabrication and testing. This new effort will focus on robustness in addition to high efficiency, specific power, and reliability. Also, some requirements introduced during the ASRG contract have also been included in the new effort, such as constant lateral loading. Due to the focus on robustness and new requirements relative to the older TDC design, the Stirling Cycle Development Project has initiated an assessment of government owned hardware to help inform requirements evolution and evaluation of future designs. While lessons learned from the ASRG flight development project have been taken into consideration, the evaluation of the TDC design had not been completed for some existing environments or relatively new requirements. To further assess the TDC design, a series of tasks were initiated to evaluate degradation for units that have operated unattended for over 105,000 hours, demonstrate robustness to a random vibration environment, characterize and evaluate performance for varying lateral load profiles. The status for each task are described.

Wilson, Scott D.↗
NASA NTRS1991

Critical technology experiment results for lightweight space heat receiver

Critical technology experiments have been performed on thermal energy storage modules in support of the NASA Advanced Solar Dynamic Brayton Heat Receiver Program. The modules, wedge-shaped canisters containing lithium fluoride (LiF), were designed to minimize the mechanical stresses that occur during the phase change of the LiF. Nickel foam inserts were placed in two of the test canisters to provide thermal conductivity enhancement and to distribute the void volume throughout the canister. A procedure was developed for reducing the nickel oxides on the nickel foam to enhance the wicking ability of the foam. The canisters were filled with LiF and closure-welded at the NASA Lewis Research Center. Two canisters, one with a nickel foam insert, the other without an insert, were thermally cycled in various orientations in a fluidized bed furnace. Computer-aided tomography was successfully used to nondestructively determine void locations in the canisters. Finally, canister dimensional stability was measured after thermal cycling with an inspection fixture.

Schneider, Michael G.↗
DOE OSTI2022

Solar Receiver with Integrated Thermal Storage for a Supercritical Carbon Dioxide Power Cycle

This project endeavors to design and demonstrate an integrated CSP system that meets the Department of Energy’s 6¢/kW-hr LCOE goal [1]. This design is based on the 10 MWe Supercritical Transformational Electric Power (STEP) engine specifications, but adaptable to any sCO 2 power module up to 10 MW e . The enabling technology to be tested is a new class of metal hydride based thermal energy storage materials which can store thermal energy in the hydrogen bonds between the metal hydride and hydrogen. This thermochemical energy storage solution provides a much greater energy density than sensible and latent energy storage enabling an integrated system design that closely linked the metal hydride to the power block. This allows the entire system to be mounted up tower to provide cost reductions. A novel metal hydride, capable of operating above 760 °C, was developed during the course of this project and thoroughly tested at a lab scale. The material’s hydrogen capacity, reaction enthalpy, thermal conductivity, and cyclic stability were measured. A demonstration test article was built that can store 2kWh of thermal energy and was coupled to Brayton Energy’s CO 2 loop where the performance of the metal hydride under commercial conditions was measured. An integrated model was created that uses the inputs from all the different sub-models in order to return an overall system LCOE using SAM. This project greatly advanced metal hydride based thermochemical energy storage technology and demonstrated its use. Previously there were no metal hydrides which were capable of operating at the proposed temperature limits (760°C), there is now a high temperature metal hydride with documented performance/stability and a path for low-cost production. Additionally, the metal hydride was tested at a scale >650x larger than what had previously been done in the lab. While not at commercial scale, it was an excellent demonstration of the technology and provided knowledge that can be leveraged for other applications.

08 HYDROGEN↗
DOE OSTI2022

Creep and Fatigue Characterization of High Strength Alloy Thin Sections in Advanced CO2 Heat Exchangers

The objective of this work was to characterize and model elevated temperature creep and fatigue behavior for thin sheet and foil forms of gamma-prime strengthened alloys in wrought form and as-processed folded and brazed constructions. This work was motivated by the demanding temperature and pressure service conditions of the GEN3 Concentrated Solar Power (CSP) and supercritical CO2 (sCO2) power cycle working fluid. More specifically, the possibility of leveraging the superior creep strength of gamma-prime alloys in folded-fin and brazed-plate heat exchanger constructions. Gamma-prime alloys represent a step-change in raw-material strength over solid-solution strengthened alloys. And the folded-fin and brazed-plate heat exchanger architecture is lightweight and leverages cost-effective material stock forms. The investigation contained two parallel paths. (1) The first is referred to as a fundamental investigation where Oak Ridge National Laboratory conducts uniaxial creep testing on thin sheet and foil in wrought form. This effort aimed to serve as a benchmark against a relatively sparse existing database and a baseline comparison for path number 2. (2) The second path is referred to as the practical investigation where Brayton Energy manufactures plate-fin heat exchangers and performs pressurized creep and fatigue testing. This effort aimed to de-risk heat exchanger manufacturing process for service under sCO2 CSP conditions. A total of 14 uniaxial creep tests were completed using Haynes 282 thin sheet and foil. A variety of heat treatments were specified to coincide with path number 2. Baseline metallography of test samples and creep strength performance are contained. Benchmarks relatively to existing thick-form Haynes 282 are made, as well as to other thin-form Nickel-based superalloys. Description of a wrought-form modeling approach for thin gamma-prime alloys is also discussed. A total of 11 pressurized creep and fatigue tests were completed successfully with Haynes 282 heat exchanger prototypes. Manufacturing processing details, testing details, testing results, and failure analysis are discussed. Additionally, creep modeling techniques to predict failure are discussed, and modeling to support technological-to-market. In conclusion, Haynes 282 foils were demonstrated to yield rupture two-to-three orders of magnitude higher than Haynes 230 foils under similar conditions. And the manufactured heat exchanger prototypes demonstrated strength similar to the wrought constituents. Both of which contribute to elevated performance potential or cost savings in practice. Discussion is included.

14 SOLAR ENERGY↗
NASA NTRS2005

Feasibility Study of a Nuclear-Stirling Plant for the Jupiter Icy Moons Orbiter

NASA is undertaking the design of a new spacecraft to explore the planet Jupiter and its three moons Calisto, Ganymede and Europa. This proposed mission, known as Jupiter Icy Moons Orbiter (JIMO) would use a nuclear reactor and an associated electrical generation system (Reactor Power Plant-RPP) to provide power to the spacecraft. The JIMO spacecraft is envisioned to use this power for science and communications as well as Electric Propulsion (EP). Among other potential power-generating concepts, previous studies have considered Thermoelectric and Brayton Power conversion systems, coupled to a liquid metal reactor for the JIMO mission. This paper will explore trades in system mass and radiator area for a nuclear reactor power conversion system, however this study will focus on Stirling power conversion. The Stirling convertor modeled in this study is based upon the Component Test Power Convertor design that was designed and operated successfully under the Civil Space Technology Initiative for use with the SP-100 nuclear reactor i the 1980's and early 1990's. The study design is such that two of the four convertors would operate at any time to generate the 100 kWe while the others are held in reserve. For this study the Stirling convertors hot-side temperature is 1050 K, would operate at a temperature ratio of 2.4 for a minimum mass system and would have a system efficiency of 29%. The Stirling convertor would generate high voltage (400 volt), 100 Hz single phase AC that is supplied to the Power Management and Distribution system. The waste hear is removed from the Stirling convertors by a flowing liquid sodium-potassium eutectic and then rejected by a shared radiator. The radiator consists of two coplanar wings, which would be deployed after the reactor is in space. System trades were performed to vary cycle state point temperatures and convertor design as well as power output. Other redundancy combinations were considered to understand the affects of convertor size and number of spares to the system mass.

Schmitz, Paul C.↗
DOE OSTI2021

Thermodynamically Stable, Plasmonic Transition Metal Oxide Nanoparticle Solar Selective Absorbers towards 95% Optical-to-Thermal Conversion Efficiency at 750 °C

Generation 3 (Gen) concentrating solar power (CSP) systems requires a high operation temperature ≥750°C to increase the power-cycle efficiency towards ≥50%. However, such a high operation temperature poses a notable challenge to high temperature materials. On the receiver side, a critical challenge is the lack of solar selective absorbers that demonstrate both high optical-to-thermal energy conversion efficiency η therm approaching 95% and long-term thermal stability at >750°C in air. Existing solar absorbers either have limited η therm ≤89% or deteriorate significantly within 500 h at 750°C; some of these also require costly vacuum deposition for stringent thickness control. Therefore, it is highly desirable to simultaneously achieve η therm ~95% AND high thermal stability at 750°C for future generations of CSP receivers. This project has investigated and developed low-cost, highly scalable spray-coated transition metal oxide nanoparticle (NP) pigmented solar selective coatings on various types of Inconel alloy tube sections that are thermodynamically stable at 750-800°C in air, maintaining η therm >94.3%(93.2%) under a solar concentration ratio of C=1000 after 60 simulated day-night cycles at 750ºC (800ºC) (1 cycle=12 h at 750 or 800°C and 12h ramping down to 25°C). We have also coated up to 48 inches long receiver tubes for preliminary solar testing under Norwich Technology’s parabolic trough systems, demonstrating notably improved performance in solar heating compared to benchmark Pyromark 2500 coatings. Two key innovations have been developed in this project: (1) We achieved an unprecedented high thermal efficiency >94% by optimizing the d-band optical absorption spectra of transition metal ions, engineering their valences and stoichiometry; (2) We were able to maintain or even slightly increase the efficiency when operating at 750°C in air by engineering the interdiffusion of transition metal ions between the coating and the Inconel substrate to our advantage. Featuring high-temperature solar spectral selectivity and thermodynamic stability in air, as well as low-cost, highly scalable solution-chemical synthesis and spray coating techniques, this innovation in solar selective absorber technology alone accounts for nearly 40% of the targeted reduction in the levelized cost of electricity (LCOE) from the receiver, thermal energy storage, and operation & maintenance combined by 2030, as proposed by the U.S. Department of Energy. For a 110 MWe CSP power plant, this LCOE reduction from the solar selective coating alone transfers to ~$\$ $1.9 M increase in annual profit based on a sales price of 10¢/kWh (or an annual sale of $50 M/year). The high solar absorptance (~98%) NP pigment materials developed in this project are equally applicable to volumetric receivers either as a coating or as bigger ceramic microspheres after sintering, potentially benefiting Gen3 falling particle CSP technologies. All these contributions facilitate the larger scale deployment of CSP systems with energy storage capability to address the intermittency issue of solar energy towards dispatchable solar electricity, bridging the temporal gap between peak solar electricity production and peak electricity consumption. The collaboration with Norwich Technologies and Brayton Energy in this project will also facilitate the future commercialization of this new solar selective coating technology developed in this SIPS project.

14 SOLAR ENERGY↗
DOE OSTI2025

Reduced order modeling of a fluidized bed particle receiver for concentrating solar power with thermal energy storage

Oxide particles can serve as both the heat transfer and thermal energy storage (TES) media for next-generation concentrating solar power (CSP) plants where high-temperature TES enables dispatchable electricity from efficient power cycles with firing temperatures above 600 °C. Transferring heat to flowing particles at such high temperatures in a MW-scale central tower receiver remains a challenge for the CSP community. For indirect receivers with external walls to contain the particles, maintaining wall temperatures below the limits of structural metal alloys requires high heat transfer coefficients between the wall and the moving particle stream. Bubbling fluidization of downward-flowing particles can sustain high bed-wall heat transfer coefficients (> 1000 W m -2 K -1 ). Using experimentally calibrated correlations for bed-wall heat transfer and vertical particle dispersion, this study implements an axially discretized zonal model of a counterflow fluidized bed receiver to explore how bubbling fluidization may enable indirect cavity particle receivers. High bed-wall heat transfer coefficients support solar fluxes on angled cavity walls > 200 kW m -2 at peak aperture fluxes of 980 kW m -2 while maintaining external wall temperatures < 950 °C. Lateral particle dispersion enables hotter particles near the receiver leading edge to mix with cooler particles further from the leading edge to lower maximum external wall temperatures. Parametric studies identify how mass fluxes, particle dispersion, and solar concentrations impact indirect receiver thermal efficiency and uniformity for a CSP plant. These studies provide a basis for the design of indirect fluidized-bed cavity receivers that can maintain particle outlet temperatures for TES above 750 °C.

14 SOLAR ENERGY↗
DOE OSTI2024

Coatings for CSP Lifetime

The feasibility and performance of tower-technology-based concentrated solar power (CSP) is highly dependent on the efficiency of the energy transformation from sun to heat at the receiver. The higher the solar absorptivity of the receiver coating, the higher the efficiency of the plant as a whole. BrightSource Energy (BSE) has developed a series of High-Performance Coating (HPC) systems in order to achieve high absorptivity over the plant lifetime (25-35 years). This requires stable coatings that are easily applicable on the large receiver surface and will maintain their optical properties under intense solar flux and thousands of heating and cooling cycles in desert conditions. Different coating formulations are required according to the differing plant conditions: receiver materials, operating conditions (temperatures, daily cycles, etc.), and environmental conditions. BSE also developed a coating for the next generation of CSP receivers, such as those being under DOE’s CSP Gen3 program, which will be operated with high temperature heat transfer fluids at temperatures of up to 800°C, which is significantly hotter than the operating temperature of current systems. Once the coating is formulated, the next challenge is evaluating its lifetime properties. BSE has found several independent failure modes that impact HPC absorptivity degradation: • Decrease in HPC optical properties due to oxidation in the receiver tubes surface below the HPC; • HPC film deterioration due to cycling of temperatures and humidity due to daily operation startup and shutdown as well as changing ambient conditions; • Mechanical degradation due to erosion by sand and wind. Existing test methods examine various aspects independently, but do not provide a combined accelerated lifetime result. Creating such a combined test suite, with a way to interpret the results to predict the coating’s projected lifetime, was the ultimate goal of this project. The project was divided into three major workstreams: lab testing (individual failure mode tests and combined failure mode tests); developing a theoretical model for aging; and validation of the test apparatus via on-sun testing in near real-world conditions at CIEMAT-PSA. Developing a test apparatus that accurately controlled the temperature while also introducing the desired solar flux proved more challenging than expected. While in the end we did succeed in creating a test apparatus that can control temperature, solar flux, and humidity, the results did not appear to accelerate the lifetime of the samples as desired. We suspect that to properly accelerate the samples we must also subject the samples to increased amounts of oxygen. Similarly, while we successfully created a combined model that is publicly available, we were unable to validate it sufficiently to feel comfortable recommending it as a general guideline.

14 SOLAR ENERGY↗