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At least 73 records · Page 4

All sources NASA NTRS DOE OSTI

DOE OSTI2023

Effects of additively manufactured surface roughness on small diameter plenums with multiple side discharges for high temperature gas turbine blade cooling applications

Combined heat and power (CHP) applications have significant environmental and economic benefits that are consistent with the goals of the U.S. Department of Energy (DOE). One area that is currently being studied includes the potential benefits of CHP turbine operation at higher turbine inlet temperatures. Internal cooling concepts enabled by additive manufacturing (AM) are of primary interest. Here, the effectiveness of internal cooling is hindered by many factors such as velocity distribution of the cooling air to the hot surface considering impingement cooling. To simulate cooling air exiting from a series of orifices for internal cooling in an airfoil, a straight smooth wall tubing with multiple side discharging orifices is used and compared to additively manufactured tubing (Ti6Al4V Grade 23) with orifice size and spacing as well as inner and outer diameters identical to the smooth wall tubing. Similar to flow discharging form perforated pipes, the flow discharged from individual orifices along the tubes in this study is found to be nonuniformly distributed, and the horizontal (axial direction) momentum can be observed from the experimental data. Discharge velocities have been measured with two-dimensional (2D) particle imaging velocimetry (PIV) and single element hot wire anemometry. Numerical analysis has also been conducted to predict the velocity distributions along the orifices in the smooth wall and additive manufacturing (AM) tubing, which are inherited with surface roughness. Numerical and measured results in this study are compared, presented, and discussed.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Assessing Low-Temperature Geothermal Play Types: Relevant Data and Play Fairway Analysis Methods

The U.S. Department of Energy (DOE) Geothermal Technologies Office (GTO) is supporting the Geothermal Heating and Cooling Geospatial Datasets and Analysis project conducted by the National Renewable Energy Laboratory (NREL) as part of a broader effort to demonstrate the multi-faceted value of integrating geothermal power and geothermal heating and cooling (GHC) technologies into national decarbonization plans and community energy plans. Currently, there is a need to establish baseline low-temperature geothermal resource datasets and evaluate methods for deploying these technologies to provide the basis for supporting private sector investment. This project is focused on collecting baseline datasets, updating conceptual models, and creating Play Fairway Analysis (PFA) workflows for low-temperature (<150 degrees Celsius) geothermal resources of different geothermal play types (i.e., sedimentary basin, orogenic belts, and radiogenic geothermal play types) that could be used for geothermal heating and cooling (GHC), combined heat and power (CHP), and other geothermal direct uses (GDU) applications. Low-temperature geothermal resources are defined as reservoirs - natural or engineered - with temperatures <150 degrees Celsius. While the focus in the NREL effort is on GHC, resources at the upper end of this temperature range can also be used for small-scale power generation. This project does not include Ground Source Heat Pumps (GSHPs) technologies because they can be effectively developed almost anywhere. Low-temperature geothermal resources have not been studied as extensively as higher- to medium-temperature geothermal resources, but there is recent interest in improving understanding of these types of resources with an uptick of interest in geothermal technologies for decarbonizing heating and cooling systems. In addition, Enhanced Geothermal Systems (EGS) and other emerging technologies for exploiting petrothermal resources have opened the possibility of utilizing deep sedimentary basin systems, where porous media provide permeability and high temperatures can be reached at great depths. This project takes the approach of classifying low- temperature geothermal resources by geothermal play type (GPT). We defined and characterized three major classes of low-temperature GPT: sedimentary basins, orogenic systems, and radiogenic systems. We develop methodologies for evaluating and analyzing the potential for these resources building off the PFA approach to de-risking geothermal exploration and characterization. The proposed PFA approach for low-temperature geothermal resources includes: 1) identifying relevant data (e.g., datasets such bottom-hole temperatures from oil and gas wells, heat flow data, Quaternary faults and stress field data, geophysical data, etc.); 2) grouping and weighting of relevant datasets into PFA criteria (e.g., geological, risk, and economic criteria); 3) uncertainty quantification; 4) developing favorability or common risk maps for low-temperature geothermal resources to identify potential locations for more focused data collection; and 5) estimating electric power generation and heating potential at those locations using the GeoRePORT Resource Size Assessment Tool (RSAT). This project should facilitate future deployment of GHC, CHP, and GDU by providing data, tools, and a workflow applicable to low-temperature geothermal resources. Increased deployment of GHC and GDU will help achieve national and local decarbonization goals.

15 GEOTHERMAL ENERGY↗

DOE OSTI2024

Scaleup and Site-Specific Engineering Design for Global Thermostat Direct Air Capture Technology

The overall goal of the project is completion of an initial design of a commercial-scale, Carbon Capture, Utilization, and Storage Direct Air Capture (CCUS-DAC) plant design at three different sites that captures a net of at least 100,000 tonnes per year (TPY) carbon dioxide (CO 2 ) from the atmosphere and considers compression and conditioning of the captured CO 2 for purpose of pipeline transportation to different geological formation sites for deep well injection and underground storage. In addition to the leading system consisting of a scaled-up Global Thermostat DAC unit, overall plant design includes a combined Heat and Power (CHP) unit integrated with a conventional liquid amine-based carbon capture system (90% capture) and compression facilities. These are considered balance of plant (BOP) systems and are required to provide low carbon-intensity steam and power to the DAC process. A second approach involving provision of DAC units modified to directly capture emissions from the CHP unit was initially assessed as an alternative and it was determined to be less mature than considered approach and not included in the scaled-up plant design efforts. Three geographically diverse continental United States locations were selected to better understand the effect of local/regional ambient conditions on scaled-up DAC system performance and project costs: Bucks, Alabama (hot wet climate), Odessa, Texas (dry hot climate), and Goose Creek, Illinois (mid continental climate). The team focused on initial engineering design activities, including the development of project design criteria, initiation of site-specific studies and investigations, completion of DAC system process and equipment design, and definition of balance of plant (BOP) engineering. The purpose of the activities were to develop Technoeconomic Analysis (TEA), Life-Cycle Analysis (LCA), and Environmental, Health, and Safety (EH&S) analysis, and Business Case Analysis (BCA) to validate that the project engineering and scale-up plans of the DAC systems, at each of the three distinct case studies considered, are technically, economically, and environmentally feasible for commercial-scale operation.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2024

Low-Temperature Geothermal Play Fairway Analysis for the Denver Basin: Preprint

This project is part of a national initiative to showcase the benefits of incorporating low-temperature geothermal resource assessment into the deployment of geothermal heating and cooling (GHC), combined heat and power (CHP), and geothermal direct use (GDU) technologies. The initiative was established to accelerate the country's decarbonization efforts by identifying potential for low-temperature geothermal resource utilization (< 150 Degrees Celsius, i.e., GHC, CHP, and GDU) in selected sedimentary basins with numerous population centers. The Play Fairway Analysis (PFA) methodologies in this study were adapted from previous PFA investigations of sedimentary basin geothermal play types (SBGPTs) that evaluated the potential for low-temperature resources (< 150 Degrees Celsius). Workflows, relevant datasets, python code, common and composite geological criteria maps are utilized to develop low-temperature geothermal resource favorability maps for the Denver Basin, a sedimentary basin spanning Colorado, Nebraska, and Wyoming. The replication of these methodologies in other SBGPTs can evaluate potential for low-temperature resources. To facilitate future assessment of low-temperature geothermal resources in SBGPTs, this project provides PFA workflows, data, tools, and favorability maps that will ultimately support the utilization of low-temperature geothermal resources in sedimentary basins.

Denver Basin↗

DOE OSTI2025

Low-Temperature Geothermal Play Fairway Analysis for the Denver Basin

This project is part of a national initiative to showcase the benefits of incorporating low-temperature geothermal resource assessment into the deployment of geothermal heating, combined heat and power (CHP), and geothermal direct-use (GDU) technologies. The initiative was established to accelerate the country's decarbonization efforts by identifying potential for low-temperature geothermal resource utilization (<150 degrees C, e.g., CHP and GDU) in selected sedimentary basins with numerous population centers. The play fairway analysis (PFA) methodologies in this study were adapted from previous PFA investigations of sedimentary basin geothermal play types (SBGPTs) that evaluated the potential for low-temperature resources (<150 degrees C). Workflows, relevant datasets, a new Python library, and common and composite geological criteria maps are utilized to develop low-temperature geothermal resource favorability maps for the Denver Basin, a sedimentary basin spanning Colorado, Nebraska, and Wyoming. The replication of these methodologies in other SBGPTs can evaluate potential for low-temperature resources. To facilitate future assessment of low-temperature geothermal resources in SBGPTs, this project provides PFA workflows, data, tools, and favorability maps that will ultimately support the utilization of low-temperature geothermal resources in sedimentary basins.

combined heat and power↗

DOE OSTI2022

2022 Combined Heat and Power/District Energy System Portfolio Meeting (Summary Report)

The U.S. Department of Energy’s (DOE’s) Advanced Manufacturing Office held the 2022 Combined Heat and Power & District Energy System Portfolio Meeting on June 7–9, 2022. The meeting brought together approximately 50 researchers from industry, national laboratories, and research institutes. The purpose of the meeting was for DOE to understand the performance of the projects being sponsored through the CHP program and the status of the technology development, which informs future program planning. This report summarizes the presentations that took place at this event.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2021

The anode supported internal cathode tubular solid oxide fuel cell: Novel production of a cell geometry for combined heat and power applications

An effective strategy for generating combined heat and power (CHP) systems is to use the combustion of hydrocarbons to provide fuel reforming and heat production for solid oxide fuel cell (SOFC) operation. Though tubular SOFCs (tSOFCs) are well suited to the thermal cycling associated with combustion systems, they have a geometric limitation which requires significant alteration to the combustion chamber. These alterations can be eliminated by producing an anode supported internal cathode-tSOFC (IC-tSOFC) which can be directly integrated into the chamber with minimal alterations. Novel methods used to produce IC-tSOFCs are discussed in this work. Scanning electron microscopy (SEM) and performance characterization are used to analyze fabricated cells. Finally, with a peak power density of 369 mW∙cm –2 , and an open circuit voltage (OCV) of 0.98 V, it is confirmed that novel production methods for IC-tSOFCs have been successful.

08 HYDROGEN↗

DOE OSTI2024

Design-Point Techno-Economics of Brayton Cycle PTES for Combined Heat and Power

Pumped thermal energy storage (PTES) systems are grid batteries that use heat pumps to create both hot and cold thermal energy stores when there is excess electricity and then use a power cycle to convert the thermal energy into electricity when there is demand for electricity. In normal operation, Joule-Brayton PTES discharges low-grade heat at temperatures useful for thermal energy consumers like district and industrial heating. Furthermore, PTES designs, like conventional combined heat and power (CHP) technology, can be modified to sacrifice some round-trip efficiency RTE to increase the temperature of heat rejection. This paper uses design-point performance and cost models that provide a detailed understanding of the efficiency and cost trade-offs of rejecting heat at various temperatures in ideal-gas Brayton PTES configurations. First, we keep the heat rejection in its nominal location in the PTES system: in the discharge cycle after the low-pressure exit of the recuperator before the cold-storage heat exchanger. Next, we move the heat rejection to the discharge turbine exit. We define design-point metrics that isolate both the cost and performance penalty associated with the hotter heat rejection and attribute it exclusively to the heat economic metrics. Finally, we estimate the performance of electric heater technology to generate heat at equivalent temperatures. We find that the levelized cost of heat, including the cost of thermal energy storage (TES) buffering the PTES and heat off-taker, compares favorable versus electric technologies and is less than the cost of natural gas for low temperature scenarios and competitive with the cost of natural gas in some regions of the contiguous United States in high temperature scenarios.

CHP↗

DOE OSTI2022

OPEN2018 (continuation of GENSETS effort)

This project has demonstrated the key components and engineering principles to support a residential scale (1 to 2 kWe) recuperated Brayton cycle generator based upon a screw compressor and screw expander. This technical work is a continuation of the previously awarded ‘GENSETS’ program. The product goal has been to achieve a 40% fuel-to-electric LHV efficiency, an 80% overall CHP efficiency, emissions qualified to the California Air Resources Board standards, and at noise levels of 55 dB or less at 1 meter. Further, the product must operate with 8,000 hour service intervals and achieve a mean-time to overhaul of 90,000 hours. Lastly, and possibly most importantly, the product must meet demanding cost targets, exhibiting a factory cost well below $1,500/kWe. After extensive aerodynamic studies under the ‘GENSETS’ program, Brayton concluded that miniature turbomachinery could not achieve an efficiency consistent with the product’s system performance goal. Given compressor and turbine efficiency targets in the range of 78 to 81%, Brayton turned to the rotary screw machines. While the justification for a screw compressor over a conventional centrifugal compressor is well supported by industry experience, the high temperature expander represented the core technology advancement. To meet the extremely high efficiency goals, an all-ceramic rotary screw expander hot section was developed and has now been tested in the laboratory. This first-of-its-kind ceramic screw expander prototype was able to demonstrate aerodynamic efficiency in line with predictions. The test article was successfully run to full stress conditions so has also validated the mechanical design of such a unit. This has opened new avenues for the commercialization of high efficiency, small scale power generation. Interest in the technology has sparked several requests for alternate uses, an invitation to present at a screw machine conference, and continued interest from parties looking to develop a product in the spirit of the original ‘GENSETS’ goals.

42 ENGINEERING↗

DOE OSTI2023

Distributed Energy Resource (DER) Reliability for Backup Electric Power Systems

Hospitals, emergency services, military bases, ports, airports, industries, commercial facilities, and others rely on backup power systems to provide electricity for their critical loads during grid outages. The purpose of this report it to provide accurate reliability information on commonly deployed distributed energy resources (DERs) to improve quantitative estimates for the reliability of these backup power systems during a grid outage. A backup power system consists of DERs, an electric distribution system with its associated switches and other devices, and mechanisms to control and manage the flow of electricity. Too often, facilities and campuses fail to properly quantify the reliability of their backup power systems. DERs are assumed to be 100% reliable, with the only concern being the availability of fuel. Such assumptions can lead to gross errors in the backup system's reliability estimates, particularly for long-duration outages. This report provides a set of estimates for reliability of emergency diesel generators (EDGs), natural gas prime generators and combined heat and power (CHP) prime movers, solar photovoltaics (PV), wind turbines, and Li-ion battery energy storage systems (BESS). The estimates are derived from empirical data when available and supplemented by modeling results when needed. These reliability estimates are for the DERs ability to provide power during a grid outage, ranging from an hour to 2 weeks.

14 SOLAR ENERGY↗

DOE OSTI2022

Effects of Synthesis Gas Concentration, Composition, and Operational Time on Tubular Solid Oxide Fuel Cell Performance

There is tremendous potential to utilize the exhaust gases and heat already present within combustion chambers to generate electrical power via solid oxide fuel cells (SOFCs). Variations in system design have been investigated as well as thorough examinations into the impacts of environmental conditions and fuel composition/concentration on SOFC performance. In an attempt to isolate the impacts of carbon monoxide and hydrogen concentration ratios within the exhaust stream, this work utilizes multi-temperature performance analyses with simulated methane combustion exhaust as fuel combined with dilute hydrogen baseline tests. These comparisons reveal the impacts of the complex reaction pathways carbon monoxide participates in when used as an SOFC fuel. Despite these complexities, performance reductions as a result of the presence of carbon monoxide are low when compared to similarly dilute hydrogen as a fuel. This provides further motivation for the continued development of SOFC-CHP systems. Stability testing performed over 80 h reveals the need for careful control of the operating environment as well as signs of carbon deposition. As a result of gas flow disruption, impacts of anode oxidation that may normally not hinder power production become significant factors in addition to coarsening of the anode material. Thermal management and strategies to minimize these impacts are a topic of future research.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2023

Urban Combined Heat and Power with Integrated Renewables and Energy Storage

District energy systems efficiently provide thermal energy to multiple buildings and facilities through a network of shared infrastructure. Frequently, district energy systems are centered around combined heat and power (CHP) plants that generate electricity as well as heating and cooling to the local buildings. By providing both electricity and thermal energy from a single fuel source and central location, these systems use less fuel, decrease energy and operational costs, and reduce the need for heating and cooling equipment in individual buildings.

EMS, CHP, GWU↗

DOE OSTI2022

A Simplified Tool for Rapidly Deploying Feasibility Analytics for the Non-Technical User

District energy systems efficiently provide thermal energy to multiple buildings and facilities through a network of shared infrastructure. Frequently, district energy systems are centered around combined heat and power (CHP) plants that generate electricity, as well as heating and cooling, to the local buildings. By providing both electricity and thermal energy from a single fuel source and central location, these systems use less fuel, decrease energy and operational costs, and reduce the need for heating and cooling equipment in individual buildings.

CHP, RCDC↗

DOE OSTI2023

Flexible Natural Gas/Hydrogen Combined Heat and Power System

CHP, ID/3D↗

DOE OSTI2024

Design-Point Techno-Economics of Brayton Cycle PTES for Combined Heat and Power

Pumped thermal energy storage (PTES) systems are grid batteries that use heat pumps to create both hot and cold thermal energy stores when there is excess electricity and then use a power cycle to convert the thermal energy into electricity when there is demand for electricity. In normal operation, Joule–Brayton PTES discharges low-grade heat at temperatures useful for thermal energy consumers like district and industrial heating. Furthermore, PTES designs, like conventional combined heat and power (CHP) technology, can be modified to sacrifice some round-trip efficiency (RTE) to increase the temperature of heat rejection. Here, this paper uses design-point performance and cost models that provide a detailed understanding of the efficiency and cost tradeoffs of rejecting heat at various temperatures in ideal-gas Brayton PTES configurations. First, we keep the heat rejection in its nominal location in the PTES system: in the discharge cycle after the low-pressure exit of the recuperator before the cold-storage heat exchanger. Next, we move the heat rejection to the discharge turbine exit. We define design-point metrics that isolate both the cost and performance penalty associated with the hotter heat rejection and attribute it exclusively to the heat economic metrics. Finally, we estimate the performance of electric heater technology to generate heat at equivalent temperatures. We find that the levelized cost of heat (LCOH), including the cost of thermal energy storage (TES) buffering the PTES and heat off-taker, compares favorably versus electric technologies and is less than the cost of natural gas for low temperature scenarios and competitive with the cost of natural gas in some regions of the contiguous U.S. in high temperature scenarios.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2021

Impact on Cycle Efficiency of Small Combined Heat and Power Plants from Increasing Firing Temperature Enabled by Additive Manufacturing of Turbine Blades and Vanes

The results of this study show that a 180°F (100°C) increase in firing temperature can increase the gas turbine efficiency by 1 percentage point without improving cooling effectiveness and add 2 additional percentage points in efficiency by using advanced turbine blades with higher internal cooling efficiency. The engine upgrades evaluated in this study show potential for increasing the CHP cycle efficiency by 3 percentage points while increasing the steam generation rate by 8%.

Uysal, Selcuk Can↗

DOE OSTI2021

Electrification of Boilers in U.S. Manufacturing

Decarbonization of the industrial heat demand through electrification where low/no-carbon electricity is used can contribute significantly to global greenhouse gas (GHG) reduction. In U.S. manufacturing, thermal processes account for approximately 75% of the total final energy demand, of which nearly 17% was consumed by conventional industrial boilers for steam generation in 2018 (this does not include boilers for combined heat and power – CHP). Steam is generally used in industry to regulate temperatures and pressures in industrial processes, dry products, strip impurities from process fluids, etc. Although all kinds of energy sources such as fossil fuels, renewables, nuclear, and electricity can generate steam, fossil fuels’-fired boilers are dominant in U.S. manufacturing. Electric boilers, which are a mature technology, have a small market share for steam generation in the global and U.S. industry (approximately 2% in U.S. manufacturing) due to several techno-economic reasons.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2022

Modular, Crushed-Rock Thermal Energy Storage Pilot Design (Final Report)

The goal of this project was to design a next-step pilot to advance near-term energy storage integrated with a fossil plant to provide a facility capable of being viable and effective in a market with growing penetration of variable renewable energy (VRE). Thermal energy storage (TES) represents an ideal technology for this purpose. The completed effort included a feasibility study to prepare for the Phase II pre-front end engineering design (pre-FEED) for implementing a crushed-rock TES system integrated with a natural gas combined cycle (NGCC) plant. The crushed rock storage technology, which is being developed by Brenmiller Energy, is a modular TES system termed bGen™, which can accommodate both thermal and electrical inputs and output steam, hot water, or hot air. For this application, the estimated efficiency is 80% thermal to thermal. For the feasibility study, the Brenmiller technology was designed to operate on a slipstream from NYPA’s Eugene W. Zeltmann Power Project (Zeltmann) NGCC plant in Astoria, New York. The projected size of the system will be up to 4 MWe with at least 4 hours of storage duration, or 16 MWh-e total. The study also included a techno-economic evaluation of a 200 MWh commercial-scale demonstration. Prior to this project, EPRI had reviewed Brenmiller’s technology, which is being built to demonstrate bGen™ at 1.7 MWe on a solar plant (Rotem) and has been designed for an NGCC facility in Italy, assessing it at technology readiness level (TRL) 5. Brenmiller is also conducting a separate 1-MWth pilot with NYPA that pairs a bGen™ module with a microturbine for a combined-heat-and-power (CHP) application to improve efficiency and provide flexibility. The next-step pilot being designed as part of this project would represent a 5-fold increase in scale, versus Rotem, and would show the technology’s ability to provide effective and economical energy storage, bringing the technology to TRL 6. This pilot would represent the next-to-last demonstration scale before the technology could be commercial ready at GWh-e scales in the 2030 timeframe. The main objective of the work completed by the Electric Power Research Institute, Inc. (EPRI), Brenmiller Energy (Brenmiller), New York Power Authority (NYPA), and United E&C (formerly AECOM) was to perform a Phase I feasibility study on the integration of a crushed-rock thermal energy storage (TES) with a fossil plant. Under this project, the EPRI-led team successfully completed a feasibility study to prepare for the potential future Phase II pre-front end engineering design (pre-FEED) to implement a crushed-rock TES system integrated with a natural gas combined cycle (NGCC) plant. Specific deliverables under this project included the Technology Maturation Plan, Conceptual Study, Techno-Economic Assessment, Technology Gap Assessment, Project Plan for Phase II (submitted as Phase II Renewal Application), Commercialization Plan, and the Final Report (this document). This Final Report includes a compilation of the various summary reports that were prepared during the 12-month schedule of the Phase I project execution under award DE-FE0032017.

03 NATURAL GAS↗