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DOE OSTI2022

Post-Irradiation Fracture Toughness Characterization of Generation II FeCrAl Alloys

FeCrAl alloys are promising candidate materials for the accident tolerant fuel (ATF) cladding application due to their exceptional resistance to oxidation in elevated temperature steam environments. Currently, limited fracture toughness data are available for the FeCrAl alloys, including the FeCrAl alloys newly developed at Oak Ridge National Laboratory (ORNL) under the U.S. Department of Energy’s Advanced Fuels Campaign (AFC) program. In this study, two Generation II candidate FeCrAl alloys, i.e., C06M (81.8Fe-10Cr-6Al-0.03Y-2Mo-0.2Si) and C36M (78.8Fe-13Cr-6Al-0.03Y-2Mo-0.2Si), were irradiated in the High Flux Isotope Reactor (HFIR) at ORNL to assess the fracture characteristics of these alloys after neutron irradiation. A total of six rabbit capsules were irradiated in HFIR at target temperatures of 200°C, 330°C, and 500°C up to target damage doses of 8 displacements per atom (dpa) and 16 dpa. Post-irradiation fracture toughness testing was performed following the Master Curve method in the ASTM E1921 standard. The main findings of this study are:1) Both the C06M and C36M alloys exhibited a similar response to irradiation concerning irradiation hardening and embrittlement.2) The irradiation temperature played different roles in terms of irradiation hardening and embrittlement for both C06M and C36M: after irradiation between 166°C and 204°C, both materials exhibited significant irradiation hardening and embrittlement; after irradiation between 315°C and 343°C, both materials showed small irradiation hardening without irradiation embrittlement. After irradiation between 501°C and 507°C, however, the irradiation softening without irradiation embrittlement was observed in both materials.3) Comparing the microhardness and Master Curve reference temperature T0q before and after neutron irradiation, we did not observe a linear correlation between the two parameters for both C06M and C36M steels. This should be mainly due to a flat response of the Master Curve reference temperature T0q to the irradiations at 166–204°C and 315–343°C ranges4) C06M showed a lower T0q, meaning better toughness, than C36M at the unirradiated condition, and such trend was kept even after neutron irradiation except for the 166–204°C irradiation after which both materials had similar T0q.5) In terms of hardening and embrittlement, the irradiation effect on both C06M and C36M appeared to saturate after an irradiation dose of 7 dpa.

Chen, Xiang↗

DOE OSTI2024

Observation of tantalum deposition and growth on TiB2 and ZrB2 from PISCES-RF deuterium and helium plasma exposures

Deuterium and helium plasma exposures on bulk TiB2 and ZrB2 samples were performed using the PISCES-RF linear plasma device. 40 and 90 eV deuterium ion plasma exposures were performed at 240 and 800 °C sample temperatures, and 80 eV helium ion plasma exposures were performed at 800 °C sample temperatures. Following plasma exposures, it was discovered that two plasma conditions (90 eV deuterium and 80 eV helium at 800 °C) resulted in thick (>200 nm) tantalum-rich (>10 at%) surface features on the targets, presumably from tantalum sourced from a tantalum adapter mask or cap used as part of the target holder. This work aims to characterize these tantalum-rich features and examine the mechanisms of impurity deposition.Plasma-induced surface morphology of the tantalum-rich surface layers depends on plasma properties and target temperature and chemistry. Greater titanium sputtering compared to zirconium resulted in more distinct surface features in the TiB2 samples compared to the ZrB2 samples via increased, prompt deposition onto tantalum surface impurities. There is still uncertainty as to why thick tantalum deposition only occurred under some plasma exposure conditions but not others; it is likely due to tantalum sputtering by a combination of boron molecules from the targets and carbon-impurities in the tantalum mask or targets. Impurity driven surface features are a well-documented phenomena in samples exposed to plasma from linear plasma device facilities—this work confirms the occurrence of this and emphasizes the need for chemistry characterization of isolated post-mortem surface features in plasma-exposed samples.

Nuckols, Lauren↗

DOE OSTI2021

COVID 19 vaccine distribution solution to the last mile challenge: Experimental and simulation studies of ultra-low temperature refrigeration system

Most COVID-19 vaccines require ambient temperature control for transportation and storage. Both Pfizer and Moderna vaccines are based on mRNA and lipid nanoparticles requiring low temperature storage. The Pfizer vaccine requires ultra-low temperature storage (between -80 °C and -60 °C), while the Moderna vaccine requires -30 °C storage. Pfizer has designed a reusable package for transportation and storage that can keep the vaccine at the target temperature for 10 days. However, the last stage of distribution is quite challenging, especially for rural or suburban areas, where local towns, pharmacy chains and hospitals may not have the infrastructure required to store the vaccine. Also, the need for a large amount of ultra-low temperature refrigeration equipment in a short time period creates tremendous pressure on the equipment suppliers. In addition, there is limited data available to address ancillary challenges of the distribution framework for both transportation and storage stages. As such, there is a need for a quick, effective, secure, and safe solution to mitigate the challenges faced by vaccine distribution logistics. The study proposes an effective, secure, and safe ultra-low temperature refrigeration solution to resolve the vaccine distribution last mile challenge. Furthermore, the approach is to utilize commercially available products, such as refrigeration container units, and retrofit them to meet the vaccine storage temperature requirement. Both experimental and simulation studies are conducted to evaluate the technical merits of this solution with the ability to control temperature at -30 °C or -70 °C as part of the last mile supply chain for vaccine candidates.

60 APPLIED LIFE SCIENCES↗

DOE OSTI2021

Evaluation and projection of long period return values of extreme daily precipitation in the CMIP5 and CMIP6 models

Using a non-stationary Generalized Extreme Value statistical method, we calculate selected extreme daily precipitation indices and their 20 year return values from the CMIP5 and CMIP6 climate models over the historical and future periods. We evaluate model performance of these indices and their return values in replicating similar quantities calculated from multiple gridded observational products. Difficulties in interpreting model quality in the context of observational uncertainties are discussed. Projections are framed in terms of specified global warming target temperatures rather than at specific times and under specific emissions scenarios. The change in framing shifts projection uncertainty due to differences in model climate sensitivity from the values of the projections to the timing of the global warming target. At their standard resolutions, we find there are no meaningful differences between the two generations of models in their quality or projections of simulated extreme daily precipitation.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

Post-Irradiation Examination on MiniFuel UCO and UO 2 TRISO Particles Irradiated in HFIR at High Power

Post-irradiation examination (PIE) of MiniFuel compacts was conducted at Oak Ridge National Laboratory (ORNL) under the Nuclear Science User Facilities project in collaboration with Kairos Power (KP) to evaluate the performance of tristructural-isotropic (TRISO) particles under high particle power and fluoride-salt-cooled high-temperature reactor (FHR)-relevant conditions. MiniFuel compacts containing low-enriched uranium oxide-uranium carbide (LEUCO), low-enriched uranium dioxide (LEUO2), and natural UCO (NUCO) kernels were irradiated for four cycles at ORNL’s High Flux Isotope Reactor (HFIR) at target temperatures between 500°C and 900°C. Post irradiation, the experiment was disassembled at ORNL to recover the MiniFuel subcapsules, which were subsequently punctured to measure fission gas release. Subcapsule disassembly allowed the recovery of components of interest, such as silicon carbide (SiC) thermometry, fuel specimens, fission product sinks, and SiC spacers. The experimental irradiation temperature was confirmed by analyzing the SiC thermometry via dilatometry. PIE on the fuel specimens included gamma spectrometry and deconsolidation leach burn leach, which were complemented by imaging techniques such as x-ray computed tomography, optical microscopy, and electron microscopy. The PIE results provide insight into TRISO particle integrity, fission product retention, coating performance, and kernel migration, informing fuel qualification for application in KP’s FHR concept.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2025

Post-Irradiation Examination on MiniFuel UCO and UO 2 TRISO Particles Irradiated in HFIR at High Power

Post-irradiation examination (PIE) of MiniFuel compacts was conducted at Oak Ridge National Laboratory (ORNL) under the Nuclear Science User Facilities project in collaboration with Kairos Power (KP) to evaluate the performance of tristructural-isotropic (TRISO) particles under high particle power and fluoride-salt-cooled high-temperature reactor (FHR)-relevant conditions. MiniFuel compacts containing low-enriched uranium oxide-uranium carbide (LEUCO), low-enriched uranium dioxide (LEUO 2 ), and natural UCO (NUCO) kernels were irradiated for four cycles at ORNL’s High Flux Isotope Reactor (HFIR) at target temperatures between 500°C and 900°C. Post irradiation, the experiment was disassembled at ORNL to recover the MiniFuel subcapsules, which were subsequently punctured to measure fission gas release. Subcapsule disassembly allowed the recovery of components of interest, such as silicon carbide (SiC) thermometry, fuel specimens, fission product sinks, and SiC spacers. The experimental irradiation temperature was confirmed by analyzing the SiC thermometry via dilatometry. PIE on the fuel specimens included gamma spectrometry and deconsolidation leach burn leach, which were complemented by imaging techniques such as x-ray computed tomography, optical microscopy, and electron microscopy. The PIE results provide insight into TRISO particle integrity, fission product retention, coating performance, and kernel migration, informing fuel qualification for application in KP’s FHR concept.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

Performance assessment for climate intervention (PACI): preliminary application to a stratospheric aerosol injection scenario

As the prospect of exceeding global temperature targets set forth in the Paris Agreement becomes more likely, methods of climate intervention are increasingly being explored. With this increased interest there is a need for an assessment process to understand the range of impacts across different scenarios against a set of performance goals in order to support policy decisions. The methodology and tools developed for Performance Assessment (PA) for nuclear waste repositories shares many similarities with the needs and requirements for a framework for climate intervention. Using PA, we outline and test an evaluation framework for climate intervention, called Performance Assessment for Climate Intervention (PACI) with a focus on Stratospheric Aerosol Injection (SAI). We define a set of key technical components for the example PACI framework which include identifying performance goals, the extent of the system, and identifying which features, events, and processes are relevant and impactful to calculating model output for the system given the performance goals. Having identified a set of performance goals, the performance of the system, including uncertainty, can then be evaluated against these goals. Using the Geoengineering Large Ensemble (GLENS) scenario, we develop a set of performance goals for monthly temperature, precipitation, drought index, soil water, solar flux, and surface runoff. The assessment assumes that targets may be framed in the context of risk-risk via a risk ratio, or the ratio of the risk of exceeding the performance goal for the SAI scenario against the risk of exceeding the performance goal for the emissions scenario. From regional responses, across multiple climate variables, it is then possible to assess which pathway carries lower risk relative to the goals. The assessment is not comprehensive but rather a demonstration of the evaluation of an SAI scenario. Future work is needed to develop a more complete assessment that would provide additional simulations to cover parametric and aleatory uncertainty and enable a deeper understanding of impacts, informed scenario selection, and allow further refinements to the approach.

climate intervention↗

DOE OSTI2022

Thermal scattering law for structure-dependent-Doppler broadening in FLASSH

Traditional Doppler broadening methods assume that target nuclei velocities follow a Maxwell-Boltzmann distribution which inherently assumes that the atoms are a free gas or that their velocities are independent of each other. This approximation is reasonable at high target temperatures and high neutron energies. However, nuclei are not independent: the lattice temperature and chemical binding will define the atomic motion. The thermal scattering law (i.e., TSL or S(α,β)) is a material property which describes the chemical binding and temperature response in terms of available momentum and energy states. In the thermal energy range, this TSL will define the thermal scattering cross sections. In the resonance region, the TSL offers a first-principles description of the probability distribution function for the velocity of the target nuclei. Using the TSL in Doppler broadening captures the structure of the material consistently from the thermal range into the resonance cross sections. In this work, both traditional free-gas and precise TSL Doppler broadening methods for resonance cross section evaluation have been implemented within the Full Law Analysis Scattering System Hub (FLASSH). This framework provides a generalized formulation for evaluating low-lying resonance data and streamlines nuclear data processing methods. TSL data generated using ab initio lattice dynamics (AILD) can be used to broaden cross section libraries in ENDF format for high-fidelity input into reactor physics calculations. These capabilities are demonstrated for the lowest absorption resonances of {sup 238}U in UO{sub 2}, UC and UN. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

Thermohydraulic Design Analysis of the Target Assembly in the Material Plasma Exposure Experiment Facility

The Material Plasma Exposure eXperiment (MPEX) project seeks to design a steady-state linear plasma facility at Oak Ridge National Laboratory that will be used to study plasma-material interactions (PMIs) at fusion prototypic levels, supporting the evaluation and development of materials for the next generation of fusion devices. This study is focused on PMI exposure of small-size neutron-irradiated specimens, which are clamped onto an actively cooled component. A thermohydraulic evaluation of a new MPEX target assembly design to assess the appropriate operation during MPEX operation is presented. To further guide the design and assess the structural integrity of the components under expected loads, preliminary thermomechanical stress analyses were also conducted. To ensure good thermal contact between the components, thermal interface materials, such as silver flexible graphite, were used in the assembly. It was found that the maximum target temperatures of 1572, 1463, and 1315 K were obtained for Grafoil thicknesses of 0.61, 0.38, and 0.25 mm, respectively. The distribution of the axial deformation at high heat fluxes showed that there are no gaps between components, indicating good contact at material interfaces. Moreover, the contact pressure between the target and other components indicated that very good contact was established at these interfaces. Furthermore, the stress-strain conditions for the target will be further used to assess the appropriate operation during MPEX experiments and gain insight into materials science phenomena during PMI experiments.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Irradiation Vehicles for Evaluating SiC/SiC Cladding Bowing Under Neutron Flux Gradients

Silicon carbide fiber–reinforced silicon carbide matrix (SiC/SiC) composites are among the most promising candidates for long term accident-tolerant nuclear fuel cladding. A key challenge related to their deployment is lateral bowing caused by differential radiation-induced swelling under dose or temperature gradients, which could obstruct coolant flow or interfere with control rod/blade movements. Although previous modeling efforts have predicted bowing behavior in light-water reactor (LWR) environments, experimental validation remains limited, especially at prototypic LWR temperatures. This study addresses that gap by irradiating six reduced-length SiC/SiC cladding tubes (~600 mm) in the High Flux Isotope Reactor (HFIR) at ~300°C, which is representative of LWR conditions. The tubes will be housed in a sealed vessel with an inert gas gap to maintain target temperatures and prevent direct coolant contact. Arranged in three pairs, each set will receive a different radiation dose (low, medium, high), with the central pair receiving ~0.1 displacements per atom (dpa)—the expected dose for peak bowing. The experiment will determine the dose-dependent bowing behavior and validate predictive finite element models. In this work, the tubes are freely suspended from pins to allow for unconstrained bowing; however, we present a concept for introducing localized constraints to represent grid spacer effects. Post-irradiation examination will include swelling measurements and profilometry to assess bowing and compare the results with model predictions. This work aims to confirm the conditions under which maximum bowing occurs so as to improve the reliability of SiC/SiC performance models in nuclear applications.

Russell, Nick [ORNL] (ORCID:0000000296099820)↗

NASA NTRS1993

Absorption heat pump for space applications

In the first part, the performance of the Absorption Heat Pump (AHP) with water-sulfuric acid and water-magnesium chloride as two new refrigerant-absorbent fluid pairs was investigated. A model was proposed for the analysis of the new working pairs in a heat pump system, subject to different temperature lifts. Computer codes were developed to calculate the Coefficient of Performance (COP) of the system with the thermodynamic properties of the working fluids obtained from the literature. The study shows the potential of water-sulfuric acid as a satisfactory replacement for water-lithium bromide in the targeted temperature range. The performance of the AHP using water-magnesium chloride as refrigerant-absorbent pair does not compare well with those obtained using water-lithium bromide. The second part concentrated on the design and testing of a simple ElectroHydrodynamic (EHD) Pump. A theoretical design model based on continuum electromechanics was analyzed to predict the performance characteristics of the EHD pump to circulate the fluid in the absorption heat pump. A numerical method of solving the governing equations was established to predict the velocity profile, pressure - flow rate relationship and efficiency of the pump. The predicted operational characteristics of the EHD pump is comparable to that of turbomachinery hardware; however, the overall efficiency of the electromagnetic pump is much lower. An experimental investigation to verify the numerical results was conducted. The pressure - flow rate performance characteristics and overall efficiency of the pump obtained experimentally agree well with the theoretical model.

Nguyen, Tuan↗

NASA NTRS1976

Development of a solar powered residential air conditioner (General optimization)

A commercially available 3-ton residential Lithium Bromide (LiBr) absorption air conditioner was modified for use with lower temperature solar heated water. The modification included removal of components such as the generator, concentration control chamber, liquid trap, and separator; and the addition of a Chrysler designed generator, an off-the-shelf LiBr-solution pump. The design goal of the modified unit was to operate with water as the heat-transfer fluid at a target temperature of 85 C (185 F), 29.4 C (85 F) cooling water inlet, producing 10.5 kW (3 tons) of cooling. Tests were performed on the system before and after modification to provide comparative data. At elevated temperatures (96 C, 205 F), the test results show that Lithium Bromide was carried into the condenser due to the extremely violent boiling and degraded the evaporator performance.

Lowen, D. J.↗

NASA NTRS1995

Calibration of the advanced microwave sounding unit-A for NOAA-K

The thermal-vacuum chamber calibration data from the Advanced Microwave Sounding Unit-A (AMSU-A) for NOAA-K, which will be launched in 1996, were analyzed to evaluate the instrument performance, including calibration accuracy, nonlinearity, and temperature sensitivity. The AMSU-A on NOAA-K consists of AMSU-A2 Protoflight Model and AMSU-A1 Flight Model 1. The results show that both models meet the instrument specifications, except the AMSU-A1 antenna beamwidths, which exceed the requirement of 3.3 +/- 10%. We also studied the instrument's radiometric characterizations which will be incorporated into the operational calibration algorithm for processing the in-orbit AMSU-A data from space. Particularly, the nonlinearity parameters which will be used for correcting the nonlinear contributions from an imperfect square-law detector were determined from this data analysis. It was found that the calibration accuracies (differences between the measured scene radiances and those calculated from a linear two-point calibration formula) are polarization-dependent. Channels with vertical polarizations show little cold biases at the lowest scene target temperature 84K, while those with horizontal polarizations all have appreciable cold biases, which can be up to 0.6K. It is unknown where these polarization-dependent cold biases originate, but it is suspected that some chamber contamination of hot radiances leaked into the cold scene target area. Further investigation in this matter is required. The existence and magnitude of nonlinearity in each channel were established and a quadratic formula for modeling these nonlinear contributions was developed. The model was characterized by a single parameter u, values of which were obtained for each channel via least-squares fit to the data. Using the best-fit u values, we performed a series of simulations of the quadratic corrections which would be expected from the space data after the launch of AMSU-A on NOAA-K. In these simulations, the cosmic background radiance corresponding to a cold space temperature 2.73K was adopted as one of the two reference points of calibration. The largest simulated nonlinear correction is about 0.3K, which occurs at channel 15 when the instrument temperature is at 38.09 deg C. Others are less than 0.2K in the remaining channels. Possible improvement for future instrument calibration is also discussed.

Mo, Tsan↗

DOE OSTI2025

Effects of ambient temperature on electric vehicle range considering battery Performance, powertrain Efficiency, and HVAC load

Here, this study investigates the impact of ambient temperature on the range of electric vehicles (EVs) by analyzing its effects on usable battery energy (UBE), heating, ventilation, and air conditioning (HVAC) energy consumption, and powertrain energy losses. Chassis dynamometer tests within a thermal chamber were conducted under various temperature conditions to investigate these impacts. The results indicate that lower temperatures lead to a decrease in UBE for lithium-ion batteries in EVs. At −18 °C, the UBE exhibited reductions of 4---8 % compared to the UBE at 22 °C. Battery thermal management strategies significantly affected the UBE loss, with different strategies resulting in distinct UBE reductions. HVAC energy consumption, especially for interior heating, proved to be the most dominant variable affecting EV driving range. Larger discrepancies between the HVAC target temperature (22 °C) and the ambient temperature increased HVAC energy usage. The type of HVAC system also influenced energy consumption, where EVs equipped with heat pumps demonstrated lower energy consumption for heating compared to those relying solely on resistance heaters. Ambient temperature also influenced motor energy consumption due to increased frictions, powertrain losses and tire rolling resistance at lower temperatures; consequently, regenerative braking energy decreased in cold conditions. Combining these effects influenced the overall energy consumption and driving range of EVs. At −18 °C, the driving range saw a substantial decrease of up to 60 % compared to 22 °C, while a slight decrease was observed at 35 °C.

Ambient Temperature↗

NASA NTRS2019

Comparisons of Cloud In-Situ Microphysical Properties of Deep Convective Clouds to Appendix D/P, Using Data from the HAIC-HIWC and HIWC RADAR I Flight Campaigns

In-situ cloud data from three international flight campaigns is compared to the new Federal Aviation Administration (FAA) Title 14 Code of Federal Regulations Part 33 Appendix D mixed-phase/glaciated environmental envelope (1), and the corresponding identical European Aviation Safety Agency (EASA) CS-25 Appendix P envelope (2) (hereafter "Appendix D/P"). Appendix D/P consists of a temperature-altitude envelope, a 99th percentile total water content (TWC99) envelope at the 17.4 Nm distance scale, a distance factor to estimate TWC99 values at other distance scales, ice crystal median mass diameter (MMD), and recommended liquid water content (LWC) levels in mixed-phase icing conditions. The dataset is from 45 flight missions in 3 tropical locations, with 472 runs in approximately 115 clouds, providing about 29,600 Nm of in-cloud data in deep convection over four targeted temperature intervals: 10, 30, 40, and 50 +5 C. The measurements span altitueds from about 17,000' to 39,000'. The comparisons will serve as a basis for regulatory and industry assessment of the efficacy of Appendix D/P.

Strapp, J. Walter↗

DOE OSTI2024

Design and Analysis of Liquid Lithium Plasma Facing Components

In this study, liquid metal (LM) on plasma-facing components (PFCs) creates a renewable protective cover enhancing power exhaust and protecting the solid substrate. Additionally, energy confinement improvement through particle pumping can be achieved in the case of liquid lithium (LL). A new variant of PFCs was recently introduced at Princeton Plasma Physics Laboratory (PPPL) where a porous wall is used to stabilize the LM surface, while using magnetohydrodynamic (MHD) drive to push the LM flow inside the component. This arrangement allows efficient heat exhaust, and enhanced control of the LM surface temperature, leading to spatial control of evaporation and condensation of LL on the plasma interface. This feature is particularly attractive when vapor shielding is introduced to allow heat flux redistribution. This system has the advantage that as the heat flux increases, the evaporation rate will increase, while decreasing heat flux will decrease the evaporation rate of lithium, ideally creating a feedback effect which could self-regulate the amount of lithium evaporated. Analytical and numerical models for LL PFCs were developed in PPPL. To calculate the target temperature distribution for the case of evaporation from the divertor, we apply an iterative process allowing two-way coupling between the fluid-kinetic analysis of plasma using SOLPS-ITER code and the flow and heat transfer analysis of the PFC using an analytical model. In the last stage, the results are validated using computational fluid dynamics (CFD) analysis with customized version of the CFX code from ANSYS. CFX was modified at PPPL to allow MHD analysis at the high magnetic field typical for fusion applications. Results of the analysis for NSTX-U tokamak conditions will be presented.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

NASA NTRS1992

X ray based displacement measurement for hostile environments

A new method on noncontacting, high temperature extensometry based on the focus and scanning of x rays is currently under development and shows great promise of overcoming limitations associated with available techniques. The chief advantage is the ability to make undisturbed measurements through stratified or flowing gases, smoke, and flame. The system is based on the ability to focus and scan low energy, hard x rays such as those emanating from copper or molybdenum sources. The x rays are focused into a narrow and intense line image which can be scanned onto targets that fluoresce secondary x ray radiation. The final goal of the system is the ability to conduct macroscopic strain measurements in hostile environments by utilizing two or more fluorescing targets. Current work is limited to displacement measurement of a single target with a resolution of 1.25 micro-m and a target temperature of 1200 C, directly through an open flame. The main advantage of the technique lies in the penetrating nature of x rays which are not affected by the presence of refracting gas layers, smoke, flame, or intense thermal radiation, all of which could render conventional extensometry methods inoperative or greatly compromise their performance.

Canistraro, Howard A.↗

DOE OSTI2025

Solar Decarbonization of Paraffin Dehydrogenation Through Particle Heat Carriers (Final Technical Report)

This project focuses on solutions to decarbonize high-temperature catalytic processes using solar thermal heat. The primary project goal is to show the validity of a moving packed bed reactor for propane dehydrogenation using catalyst particles as the heat carrier for the reaction, which can be heated by concentrated solar energy in a particle receiver. This concept, if further developed, may provide a cost-effective pathway for converting lower value gases to important chemical precursors for industrial materials using only renewable energy. The project was divided into six tasks. In Task 1, DFT calculations were performed to understand the role of Pt and Sn in the catalytic dehydrogenation reaction. In Task 2 chemical kinetics measurements were made for several catalyst formulations at high temperatures. In Task 3, the solar absorptance of catalyst particles was compared to the absorptance of commonly used materials in particle receivers. In Task 4, numerical models were developed which could predict performance of the complete system and predict specific temperatures in the system. In Task 5, a prototype system was designed, fabricated, and tested to show the validity of the concept. Task 6 concerned project management activities. Experiments with the prototype showed repeatable thermal performance at temperatures targeted for the reaction. A limited set of tests were done with active catalyst and propane dehydrogenation, showing conversion of propane to propylene with a range of conversions and selectivities. The results are promising, and the prototype designed was reliable during testing, and the team expects that further development of the prototype would yield improved results. A numerical model framework based on coupled fluid and particle mechanics was developed with high computational efficiency using GPU calculations. The model may prove highly useful for evaluating other high-temperature particle systems. However, it was determined that simpler porous media models were good fits for the needs of the current moving packed bed concept. Data showing strong solar absorption of the particles validates the plan of using existing solar particle receivers with only a change in the particle type. Catalyst investigation showed that Pt 1 Sn 3 is the most viable candidate for developing PtSn catalysts for high temperature propane dehydrogenation, considering the balance of activity, selectivity, and deactivation. This project completed an initial study of various factors needed to incorporate a moving bed catalytic reactor for propane dehydrogenation into a concentrated solar thermal particle system. Future developments may allow this technology to be scaled up and help to use solar thermal energy to decarbonize not only the propane dehydrogenation reaction, but other gas-solid catalytic reactions at similar temperatures.

14 SOLAR ENERGY↗