SEARCH · Engineering Papers
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.
One embodiment includes a powder spheroidizing method. The method includes loading a powder into a fluidized bed assembly, fluidizing at least some of the powder in the fluidized bed assembly using an inert gas, and heating the powder while fluidized in the fluidized bed assembly.
This work marks the third in a series of experiments that were in a semi-circular, gas-fluidized bed with side jets. In this work, the particles are (nominally) 1 mm ceramic beads. The bed is operated just at and slightly above and below the minimum fluidization velocity and additional fluidization is provided by two high-speed gas located on the sides of the bed near the flat, front face of the unit. Two primary measurements are taken: high-speed video recording of the front of the bed and bed pressure drop from a tap in the back of the bed. Particle Image Velocimetry (PIV) is used to determine particle motion, characterized as a mean Froude number, from the high-speed video. A CFD-DEM model of the bed is presented using the recently released MFIX-Exa code. Four model subvariants are considered using two methods of representing the jets and two drag models, both of which are calibrated to exactly match the experimentally measured minimum fluidization velocity. Although it is more difficult to determine the jet penetration depths in a straightforward manner as in the previous works using Froude number contours, the CFD-DEM results compare quite well to the PIV measurements, particularly for submodel flow Syam. Unfortunately, the good agreement of the solids-phase is overshadowed by significant disagreement in the gas-phase data. Specifically, the predicted time averaged standard deviation of the pressure drop is found to be over an order of magnitude larger than measured. Due to the low value of the measurements, just 1% of the mean bed pressure drop, it seems possible that the data is in error. On the other hand, the model may not be accurately capturing pressure attenuation through an under-fluidized region in the back of the bed. Without the possibility additional experiments to test the validity of the data, this work is simply being reported “as is” without being able to indicate which, either the simulation or the experiment, is more correct.<br>
The sandTES technology utilizes a fluidized bed counter current heat exchanger for thermal energy storage applications. Its main feature is an imposed horizontal flow of sand (SiO2) particles fluidized by a vertical air flow across a heat exchanger consisting of several horizontal rows of tubes. Past international research on heat transfer in dense fluidized beds has focused on stationary (stirred tank) systems, and there is little to no information available on the impact of longitudinal or helical fins. Previous pilot plant scale experiments at TU Wien led to the conclusion that the currently available correlations for predicting the heat transfer coefficient between the tube surface and the surrounding fluidized bed are insufficient for the horizontal sand flow imposed by the sandTES technology. Therefore, several smaller test rigs were designed in this study to investigate the influence of different tube arrangements and flow conditions on the external convective heat transfer coefficient and possible improvements by using finned tubes. It could be shown that helically finned tubes in a transversal arrangement, where the horizontal sand flow is perpendicular to the tube axes, allows an increase in the heat transfer coefficient per tube length (i.e., the virtual heat transfer coefficient) by a factor of 3.5 to about 1250 W/m2K at ambient temperature. Based on the literature, this heat transfer coefficient is expected to increase at higher temperatures. The new design criteria allow the design of compact, low-cost heat exchangers for thermal energy storage applications, in particular electro-thermal energy storage.
Long-duration energy storage technologies are being targeted to enable cost-effective, decarbonized energy systems. Particle-based thermal energy storage systems are one promising technology by storing excess electricity or heat as sensible thermal energy in inexpensive, solid, inert particles. These systems are only possible if an effective and economical particle-to-working fluid heat exchanger exists. This study predicts the performance of a proposed, direct-contact, particle-to-air, pressurized fluidized-bed heat exchanger using computational fluid dynamics. The common Eulerian-Eulerian framework for modeling fluidized beds is first benchmarked to experimental results at a previously untested operating condition and application. Then, the benchmarked model evaluates the performance of a proposed design for a commercial-scale version of the novel particle-to-air heat exchanger. The results show pressure drop and gas-phase approach temperatures are advantageous compared to other proposed designs for particle-to-air heat exchangers in the literature; approach temperatures were less than 5 °C and gas-phase pressure drop across the fluidized bed was 32 kPa. The model also highlights the importance of gas distributor design and representation in the Eulerian-Eulerian framework to control fluidization behavior. In conclusion, the model built and benchmarked in this study can be leveraged to advance the design and analysis of these heat exchangers critical to the deployment of a promising long-duration energy storage technology.
The industrial fluidized bed reactor (FBR) described here is designed to convert an aqueous solid laden stream into a consistent solid product material. Additionally, the FBR is heated to 650 °C and the aqueous reactant is spray-atomized into the fluidized bed, converting it into a granular solid through a series of heterogeneous chemical reactions. The objective of this study is to use the MFiX two-fluid model as a screening tool to investigate the effects of off-nominal conditions for the purpose of establishing performance guidelines. This information will be helpful to assess whether the identified boundaries of the system are steep or gradual. Initially, 13 independent operating parameters were sampled in a one-at-a-time manner using high, low, and base values and ranked against a set of performance criteria. Five operating parameters were found to have the largest effect (bed particle size, bed particle density, coal particle size, spray feed flow rate, and fluidizing gas flow rate) on three quantities of interest—bed differential temperature, solids velocity, and bed voidage. Latin hypercube sampling was used to generate a minimal number of random values for various combinations of input parameters. The spray feed flow rate was the most significant parameter for the temperature differences, and the coal particle and bed particle size were significant contributors. The bed particle size had the largest effect on the low velocity of the bed particles, with the coal particle size as a contributing second effect. The high solid packing shows the coal particle size with the largest effect, and significant secondary contributions from the feed flow rate and fluidizing gas flow rate. Finally, the fits to the five-dimensional Gaussian Process models were 0.7797, 0.8664, and 0.9440 for the temperature, velocity, and solids packing respectively.
Cyclones are one of the most common types of gas-solid separators used in circulating fluidized bed boilers. However, cyclones typically do not allow ash to leave the system through the cyclone exit, causing ash to build up in the fluidized bed and necessitating additional systems to remove ash that builds up in the bed. In this study, an alternative “disengager” gas-solid separator is proposed as a way of inherently separating small and large solids, resulting in a gas-solid-solid separation system where ash is allowed to leave the system along with gas while the desired fluidized bed material is retained. Unlike cyclones, which rely on centrifugal force to separate solids and gas, the disengager separates based on entrainment velocity of the particles. Upwards-flowing gas and particles strike a deflection plate and enter the disengaging chamber where particles with low terminal velocity such as ash fines flow with the gas, while larger particles such as sand fall to the bottom of the separator and are returned to the fluidized bed. In this study, several different proposed disengager configurations are simulated and compared to a typical cyclone using computational fluid dynamic (CFD) simulations. Furthermore, it was found that separation efficiency in the disengager is strongly influenced by the size of the deflection plate, rather than by the size of the unit itself. The predicted separation efficiency showed that compared to a cyclone, the disengager design allows significantly more ash to exit the system but retains a similar amount of desirable material. Additionally, the disengager was predicted to not suffer significantly more erosion that a cyclone.
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.
Both experimental and computational studies of the fluidization of high-density polyethylene (HDPE) particles in a small-scale full-loop circulating fluidized bed are conducted. Experimental measurements of pressure drop are taken at different locations along the bed. The solids circulation rate is measured with an advanced Particle Image Velocimetry (PIV) technique. The bed height of the quasi-static region in the standpipe is also measured. Comparative numerical simulations are performed with a Computational Fluid Dynamics solver utilizing a Discrete Element Method (CFD-DEM). This paper reports a detailed and direct comparison between CFD-DEM results and experimental data for realistic gas-solid fluidization in a full-loop circulating fluidized bed system. The comparison reveals good agreement with respect to system component pressure drop and inventory height in the standpipe. In addition, the effect of different drag laws applied within the CFD simulation is examined and compared with experimental results.
Fluidized bed reactors are used across a variety of industries, including for energy processes like pyrolysis that result in low-cost energy products. Design and scale-up of fluidized beds is de-risked by modeling and simulation, utilizing tools like NETL’s MFIX-Exa High-Performance Computing (HPC) code for reacting multiphase flow. This report summarizes an investigation into the breadth of problems to which MFIX-Exa may be applied, specifically with regard to low fluid velocities and the onset of fluidization. A simple fluidization study is conducted both experimentally and numerically for particles of interest, then reactor simulations are compared to cold flow experiments for uniform distributor plates. Approaches for modeling bubble caps are also presented.
To evaluate the re-design and reconfiguration of a dual-fluidized bed (DFB) gasification system into a recirculating pyrolysis reactor, Computation Fluid Dynamic (CFD) simulations of the system were conducted. The Barracuda Virtual Reactor® computational particle fluid dynamic code was used to perform simulations of the pyrolysis process. Modeling of the chemical reaction kinetics for both gas phase and solid particle phase were included. The recirculating pyrolysis reactor shown in Fig. 1a is based on a bubbling-bed biomass pyrolyzer and a riser combustor to convert the remaining char. The operational differences in the re-configuration of the DFB gasification system into a recirculating pyrolysis system for the production of bio-oil are (1) replacement of a low-surface area inert bed material with a high-surface-area bed material that has acidic properties to provide catalytic activity for the production of bio-oil with reduced oxygen content, (2) lower temperature and residence time for bio-oil production from pyrolysis, (3) replacement of the fluidization gas in the bubbling bed pyrolyzer from steam to nitrogen, and (4) the reduction of pyrolyzer freeboard volume. The bed material used for catalytic pyrolysis is Sasol 300 (300-micron dia., bulk density 0.94 kg/l, and surface area 130 m2/g) and is a theta-alumina with mild acidity. This is in comparison with previous standard bed material Carbo HSP (430-micron dia., bulk density 2.01 kg/l, and surface area 0.03 m2/g) used for gasification. For bio-oil production, pyrolysis in the bubbling bed requires temperatures in the range of 550 C in comparison with gasification temperatures near 850 C. To attain this lower temperature requires management of the energy mass balances, with control of the bed material recirculation rate between bubbling bed pyrolyzer and riser combustor, the introduction of a nitrogen purge in the pyrolyzer, and adjusting the pressure balance between the two vessels. To extract bio-oil from the pyrolysis reactor with a snorkel, two different freeboard configurations were evaluated. In Fig. 1 b the existing high freeboard configuration is shown and in Fig. 1 c the reduced freeboard design is presented. The introduction of a nitrogen purge for the high free board configuration provided the highest bio-oil production from the CFD simulations. To decrease the bed-material circulation rate, primary and secondary air on the combustor side were reduced, and the pressure on the combustor was slightly increased. A portion of the biomass and bio-oil was observed to be transported to the combustor, leading to a smaller pyrolysis yield. The control of the pyrolyzer temperature is performed by controlling the circulation rate. Good fluidization of the bubbling bed and cascade PID control are required to keep the temperature from oscillating due to large time delay experienced when changing primary and secondary air. (a) (b) (c) Figure 1. (a) Dual Fluidized Bed pyrolysis system configuration, (b) mole fraction of nonpolar biooil in high freeboard configuration, and (c) mole fraction of nonpolar bio-oil in low freeboard configuration with nitrogen purge introduced in both configurations.
Solids mixing affects thermal and concentration gradients in fluidized bed reactors and is, therefore, critical to their performance. Despite substantial effort over the past decades, understanding of solids mixing continues to be lacking because of technical limitations of diagnostics in large pilot and commercial‐scale reactors. This study is focused on investigating mixing dynamics and their dependence on operating conditions using computational fluid dynamics simulations. Toward this end, fine‐grid 3D simulations are conducted for the bubbling fluidization of three distinct Geldart B particles (1.15 mm LLDPE, 0.50 mm glass, and 0.29 mm alumina) at superficial gas velocities U/Umf = 2–4 in a pilot‐scale 50 cm diameter bed. The Two‐Fluid Model (TFM) is employed to describe the solids motion efficiently while bubbles are detected and tracked using MS3DATA. Detailed statistics of the flow‐field in and around bubbles are computed and used to describe bubble‐induced solids micromixing: solids upflow driven in the nose and wake regions while downflow along the bubble walls. Further, within these regions, the hydrodynamics are dependent only on particle and bubble characteristics, and relatively independent of the global operating conditions. Based on this finding, a predictive mechanistic, analytical model is developed which integrates bubble‐induced micromixing contributions over their size and spatial distributions to describe the gross solids circulation within the fluidized bed. Finally, it is shown that solids mixing is affected adversely in the presence of gas bypass, or throughflow, particularly in the fluidization of heavier particles. This is because of inefficient gas solids contacting as 30–50% of the superficial gas flow escapes with 2–3× shorter residence time through the bed. This is one of the first large‐scale studies where both the gas (bubble) and solids motion, and their interaction, are investigated in detail and the developed framework is useful for predicting solids mixing in large‐scale reactors as well as for analyzing mixing dynamics in complex reactive particulate systems. © 2017 American Institute of Chemical Engineers AIChE J , 63: 4316–4328, 2017
Polymersomes are being widely explored as synthetic analogs of lipid vesicles based on their enhanced stability and potential uses in a wide variety of applications in (e.g., drug delivery, cell analogs, etc.). Controlled formation of giant polymersomes for use in membrane studies and cell mimetic systems, however, is currently limited by low-yield production methodologies. Here, we describe for the first time, how the size distribution of giant poly(ethylene glycol)-poly(butadiene) (PEO-PBD) polymersomes formed by gel-assisted rehydration may be controlled based on membrane fluidization. We first show that the average diameter and size distribution of PEO-PBD polymersomes may be readily increased by increasing the temperature of the rehydration solution. Further, we describe a correlative relationship between polymersome size and membrane fluidization through the addition of sucrose during rehydration, enabling the formation of PEO-PBD polymersomes with a range of diameters, including giant-sized vesicles (>100 μm). This correlative relationship suggests that sucrose may function as a small molecule fluidizer during rehydration, enhancing polymer diffusivity during formation and increasing polymersome size. Altogether the ability to easily regulate the size of PEO-PBD polymersomes based on membrane fluidity, either through temperature or fluidizers, has broadly applicability in areas including targeted therapeutic delivery and synthetic biology.
This report describes the benchscale testing with simulant and radioactive Hanford Tank Blends, mineral product characterization and testing, and monolith testing and characterization. These projects were funded by DOE EM-31 Technology Development & Deployment (TDD) Program Technical Task Plan WP-5.2.1-2010-001 and are entitled “Fluidized Bed Steam Reformer Low-Level Waste Form Qualification”, Inter-Entity Work Order (IEWO) M0SRV00054 with Washington River Protection Solutions (WRPS) entitled “Fluidized Bed Steam Reforming Treatability Studies Using Savannah River Site (SRS) Low Activity Waste and Hanford Low Activity Waste Tank Samples”, and IEWO M0SRV00080, “Fluidized Bed Steam Reforming Waste Form Qualification Testing Using SRS Low Activity Waste and Hanford Low Activity Waste Tank Samples”. This was a multi-organizational program that included Savannah River National Laboratory (SRNL), THOR® Treatment Technologies (TTT), Pacific Northwest National Laboratory (PNNL), Oak Ridge National Laboratory (ORNL), Office of River Protection (ORP), and Washington River Protection Solutions (WRPS). The SRNL testing of the non-radioactive pilot-scale Fluidized Bed Steam Reformer (FBSR) products made by TTT, subsequent SRNL monolith formulation and testing and studies of these products, and SRNL Waste Treatment Plant Secondary Waste (WTP-SW) radioactive campaign were funded by DOE Advanced Remediation Technologies (ART) Phase 2 Project in connection with a Work-For-Others (WFO) between SRNL and TTT.
A fluidized particle single-tube solar receiver has been tested for investigating the gas-particle characteristics that enable the best operating conditions in a commercial-scale plant. The principle of the solar receiver is to fluidize the particles in a vessel – the dispenser – in which the receiver tube is plunged. The particles are flowing upward in the tube, irradiated over 1-meter height, by applying an overpressure in the dispenser. Experiments with a concentrated solar flux varying between 188 and 358 kW/m² are carried out, and the particle mass flux varied from 0 to 72 kg/(m²s). The mean particles and external tube wall temperatures in the irradiated zone are heated from the ambient to respectively 700°C and 940°C. It is shown that the temperature rise leads to a decrease of the particle volume fraction. Furthermore, a self-regulation of the system is evidenced with a short transient regime. This characteristic is essential from the operational viewpoint. The thermal efficiency of the receiver increases with the particle flow rate, reaching between 60 and 75% above 30 kg/(m²s). Several fluidization regimes are identified thanks to pressure signal analyses, like slugging, turbulent and fast fluidization, showing that regimes transitions are strongly affected by the temperature.
A fluidized-particles two-tube solar receiver was tested at ambient temperature at PROMES Laboratory to investigate the influence of an inhomogeneous solar flux density on the particle mass flow rate between the tubes. The principle of this 3rd generation solar receiver is to fluidize the particles in a container, called dispenser, in which the tubes’ bottom are immersed. The fluidized particles are flowing upward the tubes by applying an overpressure in the dispenser. Air velocities are changed inside the tubes, thanks to air mass flow controllers, to represent temperature heterogeneity between the tubes. Air velocities from 0.05 up to 0.52 m/s were tested, both in homogeneous and heterogeneous conditions. In the heterogeneous ones, the differences in air velocity between the tubes aim to mimic a difference in temperature from 20 to 100 % with homogeneous air flow rates injected. The following conclusions were drawn. First, the particle mass flux in the tubes are the same with homogeneous air velocities, each one following a calibration map previously obtained. Second, different air velocities lead to different particle mass flux. Third, the rise of the total particle mass flux diminishes the pressure in the dispenser. Four, this diminution of pressure leads to a decrease of the particle mass flow rate of the tube with the lower air velocity. This influence can lead in some cases to the stop of the fluidized bed circulation in the affected tube.
A recuperator consisting of two fluidized bed regenerators with circulating solid particles is considered for use in a Brayton cycle. These fluidized beds offer the possibility of high temperature operation if ceramic particles are used. Calculations of the efficiency and size of fluidized bed regenerators for typical values of operating parameters were made and compared to a shell and tube recuperator. The calculations indicate that the fluidized beds will be more compact than the shell and tube as well as offering a high temperature operating capability.
A recuperator consisting of two fluidized bed regenerators with circulating solid particles is considered for use in a Brayton cycle. These fluidized beds offer the possibility of high temperature operation if ceramic particles are used. Calculations of the efficiency and size of fluidized bed regenerators for typical values of operating parameters have been made and compared to a shell and tube recuperator. The calculations indicate that the fluidized beds will be more compact than the shell and tube as well as offering a high temperature operating capability.
A number of geologic processes, particularly seismic faulting, impact crater slumping, and long runout landslides, require the failure of geologic materials under differential stresses much smaller than expected on the basis of conventional rock mechanics. This paper proposes that the low strengths apparent in these phenomena are due to a state of 'acoustic fluidization' induced by a transient strong acoustic wave field. The strain rates possible in such a field are evaluated, and it is shown that acoustically fluidized debris behaves as a newtonian fluid with a viscosity in the range 100,000 to 10,000,000 P for plausible conditions. Energy gains and losses in the acoustic field are discussed, and the mechanism is shown to be effective if internal dissipation in the field gives a Q approximately greater than 100. Whether such values for Q are realized is not known at present. However, acoustic fluidization provides a qualitatively correct description of the failure of rock debris under low differential stresses in the processes of faulting, crater slumping, and long runout landslides. Acoustic fluidization thus deserves serious consideration as a possible explanation of these phenomena.