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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 667 records · Page 37
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Engineering design of a kW-scale continuous reactor-heat exchanger for high temperature discharge of particle-based thermochemical energy storage

This study investigates the theoretical design parameters and thermal performance of a kW-scale continuous oxidation reactor for high temperature (~1000 °C) thermochemical energy storage (TCES) applications. The concept comprises a counter-current particle-based system that includes a reaction zone with a heat exchanger to extract the heat produced from the oxidation reaction. Both above and below the hot reactive volume are sensible heat recuperation zones to enable the feed and removal of particles and oxidizing gas near ambient temperature during steady state operation. Two operation types for the reaction zone are studied, a fluidized bed reactor (FBR) and a moving bed reactor (MBR). The results of the parametric analysis suggest that the MBR requires a smaller volume per kW of heat produced, achieving power densities in excess of 2500 kW/m3 compared to ~ 900 kW/m 3 in the FBR. Additionally, the MBR achieves between 0.71 and 0.99 oxidation conversions compared to between 0.23 and 0.38 conversions in the FBR with the same volumes and flowrates. However, the FBR has the potential to maintain a uniform reactor temperature which can produce heat transfer fluid (HTF) outlet temperatures as high as the reactor temperature, i.e., ~1000 °C, whereas the MBR produces variable reactor temperatures that can create overheating zones and low HTF outlet temperatures (< 800 °C) depending on the operating conditions selected. Future work should aim at understanding the coupled fluid dynamics, heat and mass transfer, and thermochemical reaction for any given combination of reactor volume and contacting patterns. Here, these studies should be complemented by experimental work on particle-gas TCES reactors.

25 ENERGY STORAGE↗
DOE OSTI2015

Modeling the impact of bubbling bed hydrodynamics on tar yield and its fluctuations during biomass fast pyrolysis

The impact of bubbling bed hydrodynamics on temporal variations in the exit tar yield for biomass fast pyrolysis was investigated using computational simulations of an experimental laboratory-scale reactor. A multi-fluid computational fluid dynamics model was employed to simulate the differential conservation equations in the reactor, and this was combined with a multi-component, multi-step pyrolysis kinetics scheme for biomass to account for chemical reactions. The predicted mean tar yields at the reactor exit appear to match corresponding experimental observations. Parametric studies predicted that increasing the fluidization velocity should improve the mean tar yield but increase its temporal variations. Increases in the mean tar yield coincide with reducing the diameter of sand particles or increasing the initial sand bed height. However, trends in tar yield variability are more complex than the trends in mean yield. The standard deviation in tar yield reaches a maximum with changes in sand particle size. As a result, the standard deviation in tar yield increases with the increases in initial bed height in freely bubbling state, while reaches a maximum in slugging state.

09 BIOMASS FUELS↗
DOE OSTI2017

Production of low-oxygen bio-oil via ex situ catalytic fast pyrolysis and hydrotreating

Catalytic fast pyrolysis (CFP) bio-oils with different organic oxygen contents (4-18 wt%) were prepared in a bench-scale dual fluidized bed reactor system by ex situ CFP of southern pine over HZSM-5, and the oils were subsequently hydrotreated over a sulfided CoMo catalyst at 170 bar. The goal was to determine the impact of the CFP oil oxygen content on hydrotreating requirements. The CFP oils with higher oxygen contents included a variety of oxygenates (phenols, methoxyphenols, carbonyls, anhydrosugars) whereas oxygenates in the 4 wt% oxygen oil were almost exclusively phenols. Phenols were the most recalcitrant oxygenates during hydrotreating as well, and the hydrotreated oils consisted mainly of aromatic and partially saturated ring hydrocarbons. The temperature required to produce oil with <1% oxygen was approximately 350 °C for the CFP oil with the lowest oxygen content whereas temperatures around 400 °C were required for the other CFP oils. The carbon efficiency during hydrotreating slightly decreased as the CFP oil oxygen content increased but remained above 90% in all cases, and the carbon efficiency for the integrated process was dominated by the efficiency of the CFP process. In conclusion, a preliminary technoeconomic evaluation suggested that with the current zeolite-based CFP catalysts, it is economically beneficial to preserve carbon during CFP, at the expense of higher oxygen contents in the CFP oil.

09 BIOMASS FUELS↗
DOE OSTI2021

The intrinsic value of bioblendstocks: Prenol as a case study

Decarbonizing the transportation sector is likely to require both electrification and increased incorporation of biofuels and/or bioblendstocks. While the social and environmental benefits of bioblendstocks are well understood, their real value for the fuel producers has not been established. As such, this work considers prenol as a bioblendstock case study to identify sources of intrinsic value to fuel blenders by studying the properties of binary mixtures with gasoline components. The considered refinery blendstocks were samples of full range naphthas from the distillation, fluidized catalytic cracking, isomerization, alkylation, and reforming units. Octane numbers, Reid vapor pressure, distillation curves, and sulfur content were evaluated. Our results indicate the need for adjusting the formulation of the base fuel, depending on the interplay among the properties of the bioblendstock and those of the base fuel. Prenol increased research octane number (RON) and octane sensitivity (OS) of the base fuel, by up to 25 and 10 octane numbers, respectively. Additionally, 10 vol% prenol reduced RVP up to 2.2 psi, for the more volatile blendstock. Thus, considering prenol as a low volatility, RON/OS boosting bioblendstock, the composition of the preferred base fuel was proposed as containing reduced olefins and aromatics, and increase light fractions. The potential impact of this new gasoline formulation on refining processes and products gives rise to direct sources of value to the refiners, such as exporting products to the chemicals market, increasing the value of intermediate refinery streams, decreasing operating severity of certain refinery units, and broadening of the product suite.

09 BIOMASS FUELS↗
DOE OSTI2026

Catalytic monoterpenes conversion over Pd and zeolite to sustainable aviation fuel

Waste terpenes from wood drying are typically processed using a Regenerative Thermal Oxidizer (RTO) and converted to CO2 which is then released to the atmosphere. A novel alternative to this approach is to capture these terpenes using Fluidized Bed Concentrator (FBC) technology developed by CaptisAire which provides a useful waste carbon feedstock for subsequent upgrading. We have developed a catalytic approach where these waste terpenes (comprised of pinenes, limonene, and camphene), are converted to aromatic, and cycloalkane hydrocarbons suitable for use as a Sustainable Aviation Fuel (SAF) blendstock without the need for additional hydrogen. This provides a renewable source for aviation fuel aromatics and increases the potential blend content of renewably sourced alkanes from Hydroprocessed Esters and Fatty Acids (HEFA) and Alcohol to Jet (ATJ) processes. Terpenes were converted in a batch reactor at 260 °C and 120 psi N2 using a combination of Pd/C and H-BEA zeolite. Experimental results infer the role of the zeolite Brønsted acid to facilitate isomerization of pinenes and camphene to limonene, which then undergoes subsequent dehydro-aromatization to p-cymene using Pd/C. Hydrogen release from the dehydro-aromatization process, enables inert conversion of monoterpenes to cycloalkanes without additional hydrogen. Monoterpenes conversion to C10 aromatics (60%) and C10 cycloalkanes (40%) in an inert environment, provides a viable route for SAF blendstock sourced directly from captured waste terpenes. Transition to commercial off-the-shelf catalysts, facilitates scale-up of the terpene conversion process and improves commercial viability. We subsequently created hydrocarbon blends using HEFA or ATJ and converted terpenes, providing a 100% SAF blend with potential to replace traditional Jet-A.

Lawal, Ajibola [ORNL] (ORCID:0000000187266570)↗
DOE OSTI2017

Evaluation of fast pyrolysis feedstock conversion with a mixing paddle reactor

We have developed a pyrolysis reactor based on a unique auger-paddle configuration with heat transfer material (HTM) and proved to achieve high heating rates and fast pyrolysis. We tested ten different biomass types and obtained bio-oil yields ranging from approximately 40% for thermally treated wood, to approximately 57% for crop residues (corn stover) and 67% yield for woody feedstocks (tulip poplar). These results, as well as the solid char yields, are similar to those obtained for the same feedstock using a circulating fluidized bed. Tests conducted without HTM resulted in lower bio-oil yields (ranging from 8 to 18% decrease in yield) and higher char yields with similar changes in magnitude, which is indicative of slow pyrolysis. In addition, a comprehensive study and analysis of the material residence time and mixing characteristics of the novel auger-paddle system is presented. These results thus demonstrate that an auger-paddle configuration is capable of achieving the high heating rates required for fast pyrolysis.

09 BIOMASS FUELS↗
DOE OSTI2022

Evaluation of the energy balance of chemical looping combustion of solid fuels using CuO-based oxygen carriers

Chemical looping combustion (CLC) can inherently capture the CO2 generated during thermal energy production. When using CuO-based oxygen carriers, the reactions in both the fuel reactor (FR) and air reactor (AR) are exothermic, facilitating autothermal operation. To prevent the oxygen carrier from becoming agglomerated while ensuring a sufficient oxygen release rate, it is necessary to predict the FR temperature and remove an appropriate amount of heat from the AR when burning high-rank fuels. Here in this work, the energy balance of a CuO-based CLC system firing various solid fuels (biomass, coal, and petroleum coke) was investigated by establishing a thermodynamic model using FactSage. The energy distribution characteristics of the FR were quantified based on a virtual five-step thermodynamic sequence. The effects of fuel properties, oxygen carrier properties, and operating conditions on the energy balance were evaluated systematically. The results indicate that the temperature difference between the FR and AR is not very sensitive to the heating value of the fuel, while the CuO loading of the oxygen carrier, the heat capacity of the support material, and the flow rate of the fluidizing gas have significant impact. The insights obtained in this work will help improve the design and heat management of CLC.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2016

Bioleaching of rare earth elements from waste phosphors and cracking catalysts

Four microbial cultures were evaluated for organic acid production and their potential utility for leaching of rare earth elements (REE) from retorted phosphor powder (RPP) and spent fluidized cracking catalyst (FCC). Three of the cultures (2 bacterial, 1 fungal) were isolated from environmental and industrial materials known to contain rare earth elements. The other was the well-known and industrially important bacterium Gluconobacter oxydans. Gluconic acid was the predominant identified organic acid produced by all of the cultures; citric and acetic acid were among the other acids detected. There was also maximum REE leaching by cell free culture supernatants obtained with Gluconobacter and the FCC; 49% of total REE was recovered, with preferential recovery of lanthanum over cerium. The phosphor powder was more difficult to leach; only ~2 % total REE was leached from RPP with Gluconobacter. Tests with the RPP indicated that the extent of REE solubilization was similar whether whole cell cultures or cell-free supernatants were used. However, Gluconobacter cell-free culture supernatants with 10-15 mM gluconic acid outperformed abiotically prepared leaching solutions with 30 mM gluconic acid concentrations. Abiotic tests showed that increasing gluconic acid concentrations increased leaching efficiency; for example, total REE leaching from FCC increased from 24 to 36 to 45% when gluconic acid was increased from 10 to 30 to 90 mM. Our research shows that utilizing microorganisms that produce gluconic acid can result in effective leaching of REE from waste materials, and optimizing gluconic acid production will improve recovery.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2019

Reactive jet and cyclonic attrition analysis of ilmenite in chemical looping combustion systems

In chemical looping combustion (CLC), the chosen oxygen carrier’s (OC) reactivity maintenance and attrition propensity play key roles in determining its lifetime in such systems. Jet and cyclonic attrition are two main mechanisms of attrition in CLC systems, which typically use fluidized beds and cyclones. In contrast to standardized tests, that assess attrition characteristics under ambient and non-reacting conditions, a realistic evaluation must include the behavior under relevant high temperatures and cyclic oxidation-reduction. In this study, separate jet and cyclonic attrition test units were constructed to investigate the effects of temperature, fuel gas concentration and velocity on the performance of ilmenite, a natural ore-based OC in CLC. Testing showed that thermal and chemical effects were crucial to accurately determine the performance of ilmenite. For experiments conducted between 820°C and 970°C, the intermediate temperature of 895°C provided the best balance between high reactivity and material durability. Additionally, fuel gas concentration affected particle morphology evolution. Iron migration to the surface of the ilmenite particle was enhanced at higher fuel gas concentrations and resulted in reduced attrition rate, presumably due to sintering of the more highly reduced enriched iron phase on the particle surface. The laboratory jet and cyclonic attrition evaluation test units tested in this study can be used to investigate multiple parameters relevant for OC performance, including the degree of reduction, oxygen carrying capacity, attrition resistance, agglomeration, and optimum material operability conditions, as well as to extrapolate test data to determine OC replacement costs in a commercial CLC system.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2017

A solution algorithm for fluid–particle flows across all flow regimes

Many fluid–particle flows occurring in nature and in technological applications exhibit large variations in the local particle volume fraction. For example, in circulating fluidized beds there are regions where the particles are closepacked as well as very dilute regions where particle–particle collisions are rare. Thus, in order to simulate such fluid–particle systems, it is necessary to design a flow solver that can accurately treat all flow regimes occurring simultaneously in the same flow domain. In this work, a solution algorithm is proposed for this purpose. The algorithm is based on splitting the free-transport flux solver dynamically and locally in the flow. In close-packed to moderately dense regions, a hydrodynamic solver is employed, while in dilute to very dilute regions a kinetic-based finite-volume solver is used in conjunction with quadrature-based moment methods. To illustrate the accuracy and robustness of the proposed solution algorithm, it is implemented in OpenFOAM for particle velocity moments up to second order, and applied to simulate gravity-driven, gas–particle flows exhibiting cluster-induced turbulence. By varying the average particle volume fraction in the flow domain, it is demonstrated that the flow solver can handle seamlessly all flow regimes present in fluid–particle flows.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2017

Helium interactions with alumina formed by atomic layer deposition show potential for mitigating problems with excess helium in spent nuclear fuel

Helium gas accumulation from alpha decay during extended storage of spent fuel has potential to compromise the structural integrity the fuel. We report results obtained with surrogate nickel particles which suggest that alumina formed by atomic layer deposition can serve as a low volume-fraction, uniformly-distributed phase for retention of helium generated in fuel particles such as uranium oxide. Thin alumina layers may also form transport paths for helium in the fuel rod, which would otherwise be impermeable. Micron-scale nickel particles, representative of uranium oxide particles in their low helium solubility and compatibility with the alumina synthesis process, were homogeneously coated with alumina approximately 3–20 nm by particle atomic layer deposition (ALD) using a fluidized bed reactor. Particles were then loaded with helium at 800 °C in a tube furnace. Subsequent helium spectroscopy measurements showed that the alumina phase, or more likely a related nickel/alumina interface structure, retains helium at a density of at least 10 17 atoms/cm 3 . High resolution transmission electron microscopy revealed that the thermal treatment increased the alumina thickness and generated additional porosity. Results from Monte Carlo simulations on amorphous alumina predict the helium retention concentration at room temperature could reach 10 21 atoms/cm 3 at 400 MPa, a pressure predicted by others to be developed in uranium oxide without an alumina secondary phase. This concentration is sufficient to eliminate bubble formation in the nuclear fuel for long-term storage scenarios, for example. Finally, measurements by others of the diffusion coefficient in polycrystalline alumina indicate values several orders of magnitude higher than in uranium oxide, which then can also allow for helium transport out of the spent fuel.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

Production and characterization of TRISO fuel particles with multilayered SiC

Three distinct composite architectures of silicon carbide (SiC) and pyrocarbon (PyC) were incorporated into the SiC coating layer of tristructural-isotropic (TRISO) nuclear fuel particles. The composite architectures are meant to increase the resistance of SiC coating layer to cracking and fission product attack during operation and accident scenarios. All composite layers were produced using the existing fluidized bed chemical vapor deposition apparatus that is used for production of TRISO fuel particles without modifications. Detailed characterization of the composite microstructure was carried out via optical and electron microscopy. Nano-indentation examination confirms that mechanical properties of the SiC phase was not affected in the composite architectures, however, the resistance to crack propagation in this coating layer was greatly increased in all cases when compared to the reference monolithic coating layer. The stress required to debond the SiC-inner PyC interface in the reference TRISO particles was determined to be ~1 GPa using micropillar compression technique. The high strength may explain the ease of crack propagation from the inner PyC to SiC in the reference design. In the composite architectures, the means of crack deflection were effectively incorporated at this interface. Lastly, finite element analysis of stress evolution in the fuel particles during normal operation with the reference and composite SiC coating layer architectures did not show any significant differences between the variants.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

In situ feature analysis for large-scale multiphase flow simulations

The study of multiphase flow is essential for designing chemical reactors such as fluidized bed reactors (FBR), as a detailed understanding of hydrodynamics is critical for optimizing reactor performance and stability. An FBR allows scientists to conduct different types of chemical reactions involving multiphase materials, especially interaction between gas and solids. During such complex chemical processes, the formation of void regions in the reactor, generally termed as bubbles, is an important phenomenon. The study of these bubbles has a deep implication in predicting the reactor’s overall efficiency. But physical experiments needed to understand bubble dynamics are costly and non-trivial due to the technical difficulties involved and harsh working conditions of the reactors. Therefore, to study such chemical processes and bubble dynamics, a state-of-the-art computational simulation MFIX-Exa is being developed. Despite the proven accuracy of MFIX-Exa in modeling bubbling phenomena, the large-scale output data prohibits the use of traditional post hoc analysis capabilities in both storage and I/O time. Herein, to address these issues and allow the application scientists to explore the bubble dynamics in an efficient and timely manner, we have developed an end-to-end analytics pipeline that enables in situ detection of bubbles, followed by a flexible post hoc visual exploration methodology of bubble dynamics. The proposed method enables interactive analysis of bubbles, along with quantification of several bubble characteristics, enabling experts to understand the bubble interactions in detail. Positive feedback from the experts has indicated the efficacy of the proposed approach for exploring bubble dynamics in very-large-scale multiphase flow simulations.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2024

Impact of anisotropy on TRISO fuel performance

Manufacturing of tristructural isotropic (TRISO) particles involves the deposition of pyrolytic carbon (PyC) and silicon carbide (SiC) layers using the fluidized bed chemical vapor deposition (CVD) process. The CVD process is known to generate polycrystalline layers with crystallographic textures, which imparts anisotropic thermophysical properties to the layers. Past studies have shown the risk for particle failure increases with an increase in anisotropy. The limit beyond which the anisotropy of PyC layers becomes unacceptable due to failure risk has been identified as a high-priority knowledge gap. This work presents a first systematic study on the effects of anisotropic thermal and mechanical properties on TRISO fuel performance. This computational study, performed using the fuel performance code BISON, investigates how the anisotropy in elasticity and thermal properties affect the stresses, temperature, and failure of a TRISO particle. The influence of other factors, such as operating temperature and particle geometry on the anisotropy effects, also has been analyzed. The studies utilize the recently published anisotropic elasticity and thermal behavior models for TRISO PyC and SiC layers implemented using tensors with full anisotropic capability. The spherical TRISO particles with anisotropic properties were found to have greater maximum tensile stress and significantly higher failure probability than the spherical particles with isotropic properties. In conclusion, the fuel performance predicted using these recently developed models was found to be comparable with the performance obtained using the historical models.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Thermal oxidation of nuclear graphite and pyrolytic carbon coatings

The oxidation of pyrolytic carbon (PyC) deposited via fluidized bed chemical vapor deposition was characterized and compared with that of standard nuclear-grade graphite. The materials were heated at 700 to 1000 °C in a thermogravimetric analysis system under 20% v/v O 2 flow, allowing for direct comparison of dynamic oxidative mass change in each material. Further, three different PyC samples fabricated under different conditions exhibited variation in total mass loss and mass loss rate, varying by as much as 709 mg/cm 2 in total mass loss and 14.2 (mg/cm 2 )/min in mass loss rate at a single temperature. These variations highlight the correlation between PyC microstructure/defect density and oxidation susceptibility. Additionally, changes in the microstructure and composition between PyC and graphite were characterized via scanning electron microscopy and correlated to the mass loss results. The results of this work have implications toward the safety of tristructural isotropic (TRISO) and other coated particle fuels, especially under off-normal conditions, given the limited information that exists about the oxidation behavior of PyC.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Polysiloxane coatings on microspheres based on Multiphase Flow with Interface Exchange-Discrete Element Modelling

Polysiloxane coatings on yttria stabilized zirconia (YSZ) microspheres of 500 μm were simulated in a spout fluidized bed coater using Multiphase Flow with Interface Exchange-Discrete Element Modelling (MFiX-DEM). In this work, two different coater configurations were developed to study the influence of gas velocity and its distribution on particle dynamics. The presence of the Wurster tube not only enhances the distribution but also increases the overall residence time of the particles. Investigations were also carried out with different Wurster tube positions (normal, 10% and 20% lowered from its initial position). Among these, 20% lowered Wurster tube position demonstrated the most effective coating process. The effects of gas inlet pressure on the average gas velocity and the distribution of particles were analyzed. More than 97% of the particles can be retained. The derived results, including average gas velocity, particle retention percentage, and distribution of particles with gas velocity, are being used to guide the experimental work in obtaining defect-free coatings for YSZ microspheres.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Gaussian integral method for void fraction

Here, a novel method, the Gaussian Integral Method (GIM), is presented for calculating void fractions in Computational Fluid Dynamics–Discrete Element Method (CFD-DEM) simulations. GIM is versatile and applicable to various grid types, including structured and unstructured polyhedral meshes, without requiring special boundary treatments. An optimization technique is introduced to make GIM independent of grid resolution and type. The method is validated against experimental data from a fluidized bed, demonstrating that GIM produces realistic simulations closely resembling experimental observations. Additionally, unstructured polyhedral grids using GIM outperform structured grids of equivalent resolution, yielding results more aligned with experimental data. The gradient of the void fraction is computed in the CFD solver and utilized in the DEM solver for precise estimation at particle locations. Overall, GIM provides an effective solution for void fraction calculations in particulate media simulations with complex geometries, enhancing the accuracy and applicability of CFD-DEM simulations for industrial processes.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗