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At least 721 records · Page 40

Energy Efficient Engine (E3) combustion system component technology performance report

The Energy Efficient Engine (E3) combustor effort was conducted as part of the overall NASA/GE E3 Program. This effort included the selection of an advanced double-annular combustion system design. The primary intent of this effort was to evolve a design that meets the stringent emissions and life goals of the E3, as well as all of the usual performance requirements of combustion systems for modern turbofan engines. Numerous detailed design studies were conducted to define the features of the combustion system design. Development test hardware was fabricated, and an extensive testing effort was undertaken to evaluate the combustion system subcomponents in order to verify and refine the design. Technology derived from this effort was incorporated into the engine combustion hardware design. The advanced engine combustion system was then evaluated in component testing to verify the design intent. What evolved from this effort was an advanced combustion system capable of satisfying all of the combustion system design objectives and requirements of the E3.

Burrus, D. L.↗

Advanced Energy Harvesting Control Schemes for Marine Renewable Energy Devices

The Advanced Energy Harvesting Control Schemes for Marine Renewable Energy Devices (Project) investigated, analyzed and modeled advanced turbine control schemes with the objective of increasing the energy harvested by hydrokinetic turbines in turbulent flow. Ocean Renewable Power Company (ORPC) implemented and validated a feedforward controller to increase power capture; and applied and tested the controls on ORPC’s RivGen® Power Systems in Igiugig, Alaska. Assessments of performance improvements were made for the RivGen® in the Igiugig environment and for ORPC’s TidGen® Power System in a reference tidal environment. Annualized Energy Production (AEP) and Levelized Cost of Energy (LCOE) improvements associated with implementation of the recommended control methodology were made for the TidGen® Power System in the DOE reference tidal environment. System Performance Advancement (SPA) goals were selected for the project. SPA targets were to improve Power to Weight Ratio (PWR) and system Availability, with the intention of reducing Levelized Cost of Electricity (LCOE). This project focused primarily reducing in PWR. Reductions in PWR of 25.5% were achieved. Reductions of 20.3% in LCOE were achieved. This project evaluated four types of controllers which were tested in simulation, emulation, a laboratory flume, and the field. The adaptive Kω2 controller performs similarly to the non-adaptive version of the same controller and may be useful in tidal channels where the mean velocity is continually evolving. Trends in simulation were largely verified through experiments, which also provided the opportunity to test assumptions about turbine responsiveness and control resilience to varying scales of turbulence. Laboratory experiments provided an essential stepping stone between simulation and implementation on a field-scale turbine. Experiments also demonstrated that using “energy loss” as a metric to differentiate between well-designed controllers operating at an optimal tip-speed ratio set-point is difficult, which anticipated the outcome from field experiments. The clear message is that the feedforward Kω2 controller out-performs the feedback controllers in almost all aspects and modes of evaluation. The controllers proved a substantial improvement over the baseline performance of the TidGen® turbine, in terms of energy capture. The effects of noise-contaminated angular velocity signals were investigated and validated by simulation as an explanation for the performance limitations observed for TidGen® turbine operations in Eastport, Maine. Measurements of loads performed as part of the laboratory testing indicate that there are limited differences in average axial thrust force between control architectures. This suggests that none of the control strategies are likely to substantially affect loads on the turbine support structure. Velocity measurements during the ORPC RivGen® turbine deployment at Igiugig, Alaska, in 2014 were used to assess the variability of the river flow. Results suggest that the river flow is approximately steady, in the mean sense, at any particular location in the river, with random turbulent fluctuations that are around 10% of the mean flow. The mean flow in the center channel of the river is 2.5 m/s, with reductions near the riverbanks and in the shallows. Spectral analysis and lagged correlation results indicate that temporal fluctuations at a given point are dominated by large scale fluctuations, such that measurements at the turbine location are just as useful for inflow control implementation as upstream measurements. At this site, and likely at many other river sites, flow is generally steady at a given location, but flow varies dramatically between locations, particularly laterally across the river. The primary result is that a lateral change in position of a few meters results in changes to flow speed that far exceed the turbulence fluctuations at any given location. The turbulence is dominated by long time scales. Following final system tests, the RivGen® device was submerged and each evaluated controller was tested across a range of gain/set point values and filter configurations for a minimum of 5 minutes, with longer runs attempted for well-performing cases. In addition to testing controllers during the 2015 deployment season, LGL Alaska Research Associates Inc. (LGL) performed a fish monitoring study in compliance with Alaska Department of Fish and Game fisheries habitat permit for the project. During the season, LGL reviewed 10% of 179 one-hour blocks of footage (6 minutes on the hour) and documented a total of over 1200 fish in the vicinity of the RivGen® device, including over 800 salmon smolt and over 350 adult salmon. No evidence of adverse effects including passage delay by upstream migrating salmon was noted. This is an important result for future deployments and has a direct impact on commercial system designs.

16 TIDAL AND WAVE POWER↗

Performance optimization of a bendable parabolic cylinder collimating X-ray mirror for the ALS micro-XAS beamline 10.3.2

The Advanced Light Source (ALS) beamline (BL) 10.3.2 is an apparatus for X-ray microprobe spectroscopy and diffraction experiments, operating in the energy range 2.4–17 keV. The performance of the beamline, namely the spatial and energy resolutions of the measurements, depends significantly on the collimation quality of light incident on the monochromator. In the BL 10.3.2 end-station, the synchrotron source is imaged 1:1 onto a set of roll slits which form a virtual source. The light from this source is collimated in the vertical direction by a bendable parabolic cylinder mirror. Details are presented of the mirror design, which allows for precision assembly, alignment and shaping of the mirror, as well as for extending of the mirror operating lifetime by a factor of ~10. Assembly, mirror optimal shaping and preliminary alignment were performed ex situ in the ALS X-ray Optics Laboratory (XROL). Using an original method for optimal ex situ characterization and setting of bendable X-ray optics developed at the XROL, a root-mean-square (RMS) residual surface slope error of 0.31 µrad with respect to the desired parabola, and an RMS residual height error of less than 3 nm were achieved. Once in place at the beamline, deviations from the designed optical geometry ( e.g. due to the tolerances for setting the distance to the virtual source, the grazing incidence angle, the transverse position) and/or mirror shape ( e.g. due to a heat load deformation) may appear. Due to the errors, on installation the energy spread from the monochromator is typically a few electron-volts. Here, a new technique developed and successfully implemented for at-wavelength ( in situ ) fine optimal tuning of the mirror, enabling us to reduce the collimation-induced energy spread to ~0.05 eV, is described.

43 PARTICLE ACCELERATORS↗

Center for Renewable Energy and Alternative Transportation Technologies (CREATT) (Final Report)

The Center for Renewable Energy and Alternative Transportation Technologies (CREATT) was established to advance the state of the art in knowledge and education on critical technologies that support a renewable energy future. Our research and education efforts have focused on alternative energy systems, energy storage systems, and research on battery and hybrid energy storage systems.This report details the Center's progress in the following specific areas: Development of a battery laboratory; Development of a demonstration system for compressed air energy storage; Development of electric propulsion test systems; Battery storage systems; Thermal management of battery packs; and Construction of a micro-grid to support real-world performance monitoring of a renewable energy system.

25 ENERGY STORAGE↗

Particle Image Velocimetry Measurements in a Wire-Wrapped 61-Pin Hexagonal Fuel Bundle

Liquid metal fast reactor fuel assemblies using sodium as a coolant typically utilize a tightly packed triangular lattice of fuel pins enclosed in a hexagonal duct. The fuel pins are typically wrapped with a helical wire spacer. The primary function of the wire spacers is to maintain a gap between neighboring fuel pins. They also mitigate vortex-induced vibration and enhance sub-channel mixing to increase convective heat transfer. Many experiments have been performed to study thermal-hydraulic characteristics, primarily pressure drops, of the wire-wrapped fuel bundles. Novendstern developed a semi-empirical model to predict pressure losses in a hexagonal array of wire-wrapped pins in the turbulent flow regime. Rehme proposed pressure drop correlations for a wide range of geometrical parameters, such as pitch-to-diameter ratio P/D from 1.125 to 1.417, lead-to-wire diameter ratio H / dm from 6 to 45, and number of pins n from 7 to 61. Cheng and Todreas introduced their hydrodynamic models for subchannel friction factors and mixing parameters in a 37-pin fuel bundle, which covered the laminar, transition and turbulent flow regimes. Computational fluid dynamics (CFD) offers an opportunity to validate the above correlations and investigate the flow characteristics in the subchannels. Several numerical studies of the wire-wrapped fuel bundles have been performed and most of them are Reynolds-Averaged Navier-Stokes (RANS) based simulations with various turbulence models. Ahmad and Kim performed RANS simulations of 7- and 19-pin bundles using the k-omega SST turbulent model, while Gajapathy et al. performed RANS simulations on 7-pin bundles using the k-epsilons model. Recently, Fischer et al. carried out large-eddy simulation (LES) calculations on wire-wrapped fuel bundles to obtain higher-resolution numerical solutions of subchannel behavior. The geometrical complexity of the hexagonal wire-wrapped fuel bundle has limited experimental activities to pressure drop measurements. A database of pressure drops and flow-field measurements in a 61-pin wire-wrapped hexagonal fuel bundle is not available to benchmark the existing correlations and validate the CFD calculations. Texas A and M University is conducting isothermal flow experiments in a wire-wrapped 61-pin hexagonal fuel bundle to support the research on advanced nuclear fuel development sponsored by the Department of Energy (DOE). The purpose of these tests is to perform high spatial and temporal resolution measurements of the flow and pressure measurements at different locations in the fuel bundle. The experimental facility employs matched-index-of-refraction (MIR) techniques and laser diagnostic velocity measurement techniques such as particle image velocimetry (PIV) and laser Doppler velocimetry (LDV). The result of this experimental activity will be an experimental database of pressure and flow-field measurements that will be suitable for validating CFD computer codes. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Characteristics and Performance of Existing Load Disaggregation Technologies

Non-intrusive load monitoring (NILM) or non-intrusive appliance load monitoring (NIALM) is an analytic approach to disaggregate building loads based on a single metering point. This advanced load monitoring and disaggregation technique has the potential to provide an alternative solution to high-priced traditional sub-metering and enable innovative approaches for energy conservation, energy efficiency, and demand response. However, since the inception of the concept in the 1980’s, evaluations of these technologies have focused on reporting performance accuracy without investigating sources of inaccuracies or fully understanding and articulating the meaning of the metrics used to quantify performance. As a result, the market for, as well as, advances in these technologies have been slowly maturing. To improve the market for these NILM technologies, there has to be confidence that the deployment will lead to benefits. In reality, every end-user and application that this technology may enable does not require the highest levels of performance accuracy to produce benefits. Also, there are other important characteristics that need to be considered, which may affect the appeal of NILM products to certain market targets (i.e. residential and commercial building consumers) and the suitability for particular applications. These characteristics include the following: 1) ease of use, the level of expertise/bandwidth required to properly use the product; 2) ease of installation, the level of expertise required to install along with hardware needs that impact product cost; and 3) ability to inform decisions and actions, whether the energy outputs received by end-users (e.g. third party applications, residential users, building operators, etc.) empower decisions and actions to be taken at time frames required for certain applications. Therefore, stakeholders, researchers, and other interested parties should be kept abreast of the evolving capabilities, uses, and characteristics of NILM that make them attractive for certain building environments and different classes of end-users. The intent of this report is to raise awareness of trending NILM approaches. Additionally, three existing technologies were acquired and evaluated using the Residential Building Stock Assessment (RBSA) owner-occupied test bed operated by the Northwest Energy Efficiency Alliance (NEEA) to understand performance accuracy of current NILM products under realistic conditions. Based on this field study experience, the characteristics exhibited by the NILM products included in the assessment are also discussed in this report in terms of ease of use, ease of installation, ability to inform decisions and actions. Results of the analysis performed to investigate the accuracy of the participating NILM products in estimating energy use of individual appliances are also presented.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Engineered Transport in Microporous Materials and Membranes for Clean Energy Technologies

Many forward-looking clean-energy technologies hinge on the development of scalable and efficient membrane-based separations. Ongoing investment in the basic research of microporous materials is beginning to pay dividends in membrane technology maturation. Specifically, improvements in membrane selectivity, permeability, and durability are being leveraged for more efficient carbon capture, desalination, and energy storage, and the market adoption of membranes in those areas appears to be on the horizon. Herein, an overview of the microporous materials chemistry driving advanced membrane development, the clean-energy separations employing them, and the theoretical underpinnings tying membrane performance to membrane structure across multiple length scales is provided. The interplay of pore architecture and chemistry for a given set of analytes emerges as a critical design consideration dictating mass transport outcomes. Also discussed are opportunities and outstanding challenges in the field, including high-flux 2D molecular-sieving membranes, phase-change adsorbents as performance-enhancing components in composite membranes, and the need for quantitative metrologies for understanding mass transport in heterophasic materials and in micropores with unusual chemical interactions with analytes of interest.

36 MATERIALS SCIENCE↗

A theoretical study of the bonding properties of R 4 Sb 3 compounds

Here, this study investigates the electronic structure and bonding properties of rare-earth antimonide compounds, specifically Yb 4 Sb 3 and La 4 Sb 3 , utilizing density functional theory calculations. The analysis reveals that Yb 4 Sb 3 exhibits a predominantly ionic character whereas La 4 Sb 3 displays a greater degree of covalent bonding. Moreover, the presence of divalent ytterbium leads to p-type conduction at high temperatures in Yb 4 Sb 3 . Conversely, La 4 Sb 3 displays n-type conduction because of a larger electronic transfer from the rare-earth metal towards antimony. These findings provide valuable insights into the structural and electronic properties that govern the performance of R 4 Sb 3 compounds, contributing to the development of advanced materials for thermoelectric energy conversion.

36 MATERIALS SCIENCE↗

Thermally-Conductive and Mechanically-Robust Graphene Nanoplatelet Reinforced UO 2 Composite Nuclear Fuels

Low thermal transport behavior along the radial direction of nuclear fuel pellets and pellet-cladding mechanical interaction significantly impact fuel performance and the safety of current nuclear energy systems. Here we report a new strategy of advanced fuel design in which highly thermally-conductive and mechanically-robust graphene nanoplatelets are incorporated into UO 2 fuel matrix to improve fuel thermal-mechanical properties. The 2D geometry of the graphene nanoplatelets enables a unique lamellar structure upon fuel consolidation by spark plasma sintering. The thermal conductivity along the radial direction of the sintered fuel pellets at room temperature reaches 12.7 and 19.1 wm –1 K –1 at 1 wt.% and 5 wt.% loadings of the graphene nanoplatelets, respectively, representing at least 74% and 162% enhancements as compared to pure UO 2 fuel pellets. Indentation testing suggests great capability of the 2D graphene nanoplatelets to deflect and pin crack propagation, drastically improving the crack propagation resistance of fuel matrix. Here, the estimated indentation fracture toughness reaches 3.5 MPa·m 1/2 by 1 wt.% loading of graphene nano-platelets, representing a 150% improvement over 1.4 MPa·m 1/2 for pure UO 2 fuel pellets. Isothermal annealing of the composite fuel indicates that the graphene nano-platelet is able to retain its structure and properties against reaction with UO 2 matrix up to 1150 °C.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

The mechanism behind the high radiation tolerance of Fe-Cr alloys

With the great demand for high radiation tolerant materials for advanced nuclear energy technologies, Fe-Cr alloys are at the forefront with long standing validated performance. Yet, the real mechanism behind their high radiation resistance is in question and understanding the effect of varying Cr percentage is a grand challenge limiting further improvements. Here we applied depth resolved atomic scale probe of defects to uncover the real mechanism on how Cr improves radiation resistance and explain the controversial impact of increasing Cr percentage. By combining depth-resolved positron annihilation lifetime spectroscopy and Doppler broadening spectroscopy we investigated the effect of Cr alloying on the formation and evolution of atomic size clusters induced by ion irradiation in Fe. We also used atom probe tomography to investigate the possible presence of Cr clusters or a’ phase with high Cr composition. The study reveals that the well-known resistance to radiation in Fe-Cr alloys arises from the stabilization of vacancy clusters around Cr atoms which act as sinks for radiation-induced defects. Thus, Cr atoms do not provide a direct sink for interstitials; rather defect complexes for that consist of Cr atoms and vacancies in turn act as sinks for irradiation-induced vacancies and interstitials. Most importantly, we find that lower amounts of Cr create smaller, uniformly distributed defect clusters that act as efficient sinks for radiation damage, but larger quantities of Cr form a defect structure that is less homogenous in size and spatial distribution, resulting in less efficient damage recombination. No evidence of phase a’ was found before or after irradiation, which indicates that it does not contribute to the observed radiation tolerance.

36 MATERIALS SCIENCE↗

Distributed fiber-optic sensing in a subscale high-temperature superconducting dipole magnet

High-temperature superconductors, such as REBa2Cu3O7−x (REBCO, RE = rare earth), are becoming pivotal for high-field magnet technology for future circular colliders and compact fusion reactors. The U.S. Magnet Development Program, in collaboration with industry, is developing REBCO magnet technology using round conductors consisting of multiple REBCO tapes. For these multi-tape cables, traditional instrumentation, such as voltage taps and resistive strain gauges, become insufficient to help measure and understand the performance-limiting factors in these model magnets. Distributed fiber-optic sensing (DFOS) is a potential solution to address this challenge. Although DFOS is well established for various applications, measuring temperature and strain in high-temperature superconducting magnets is in its infancy. Here we report the detailed implementation and test results of DFOS based on Rayleigh scattering in a subscale canted cosθ (CCT) dipole magnet using high-temperature superconducting CORC® wires. We co-wound optical fibers in each layer of the CCT magnet and compared different types of commercial fibers and mold-release agents to reduce the power attenuation in the fibers. The DFOS allowed us to measure mechanical deformation and temperature along the conductor during tests at 77 and 4.2 K. The measured strain agreed quantitively with a finite-element mechanical model of the subscale magnet. Our results indicate that DFOS can effectively identify locations of strain and temperature changes, offering unique insight into magnet performance that can advance our understanding and development of the REBCO magnet technology for high-energy physics and fusion applications.

Luo, Linqing↗

Energy Storage to Enable Electricity as a Commodity

A lack of large-scale economical storage, demand-side flexibility, and the need to instantaneously balance supply and demand cause challenges for electricity as a commodity. With typical commodities, stock from periods of high production can be stored and sold during low production, smoothing demand and supply shocks. In electricity markets, high storage costs have long outweighed benefits, negating convenience yield; no-arbitrage models do not apply, and typical hedging strategies cannot be performed due to infinite carry costs. However, the mechanics of energy trading are changing due to advancing storage technologies, more price-responsive demands, and virtual bidding in electricity markets, shaping a system where electricity storage can be valued on factors other than diurnal arbitrage. We examine the valuation of electricity storage through the lens of commodity markets to assess the impacts of large-scale storage deployment.

energy storage↗

Design and Construction of a 1/15th Scale Wave Tank Model of the Azura Commercial Wave Energy Converter

The design of a 1/15th geometrically scaled wave tank model of the Azura(TM) commercial-scale wave energy device is presented. The objectives of the wave tank tests, conducted at the University of Maine Harlod Alfond Wind/Wave Ocean Engineering Lab (W2), included verification of the Azura's energy capture in irregular waves, evaluation of performance in survival wave conditions, and testing of two advanced control algorithms. Due to the difficulty in properly Froude Scaling a hydraulic system, the model used a direct-drive rotary motor/generator power take-off (PTO), with the dynamics of the hydraulic PTO included via a hardware-in-the-loop simulation. This PTO implementation led to additional design requirements being imposed on the model drivetrain. In addition to the model PTO design, the instrumentation design, structural design, and test plans are presented. The resulting model and PTO achieved a high level of controllability, and accurately emulated the dynamics of the hydraulic PTO of the full-scale Azura prototype.

16 TIDAL AND WAVE POWER↗

Multiplexed Optical Fiber Sensors for Coal Fired Advanced Fossil Energy Systems

This report summarizes technical progress on the program Multiplexed Optical Fiber Sensors for Coal Fired Advanced Fossil Energy Systems funded by the National Energy Technology Laboratory of the U.S. Department of Energy, and performed jointly by the Center for Photonics Technology of the Bradley Department of Electrical and Computer Engineering and the Department of Materials Science and Engineering at Virginia Tech. This three-year project started on October 1, 2008. In the project, a fiber optical sensing system based on intrinsic Fabry-Perot Interferometer (IFPI) was developed for strain and temperature measurements for Ultra Supercritical boiler condition assessment. Investigations were focused on sensor design, fabrication, attachment techniques and novel materials for high temperature and strain measurements. At the start of the project, the technical requirements for the sensing technology were determined together with our industrial partner Alstom Power. As is demonstrated in Chapter 4, all the technical requirements are successfully met. The success of the technology extended beyond laboratory test; its capability was further validated through the field test at DOE NETL, in which the sensors yielded distributed temperature mapping of a testing coupon installed in the turbine test rig. The measurement results agreed well with prior results generated with thermocouples. In this project, significant improvements were made to the IFPI sensor technology by splicing condition optimization, transmission loss reduction, sensor signal demodulation and sensor system design.

01 COAL, LIGNITE, AND PEAT↗

Deployment of Alumina Forming Austenitic (AFA) Stainless Steel

The purpose of the project was to accelerate the deployment and further the development of a new family of heat-resistant alloys developed at ORNL: alumina-forming austenitic (AFA) stainless steels. Initial laboratory scale evaluation indicated that AFA alloys possess exceptional high-temperature oxidation resistance while retaining creep properties similar to other advanced austenitic stainless steels. The AFA steels therefore represent a low-cost alternative to Ni-base alloys and a high performance alternative to conventional advanced austenitic steels. Deployment of AFA steels into turbine and other energy-related applications can lead to improved efficiencies by achieving higher operating temperatures and/or improved durability and component lifetime at costs comparable to currently used alloys. The development and scale up of optimized AFA alloy compositions in both wrought and cast forms, including generation of a database of thermo-physical, mechanical, welding/joining, and high-temperature corrosion properties was needed to enable consideration and adoption of these new materials in applications ranging from turbines, heat exchangers, and fuel cells to boilers and chemical/petrochemical processing. The project consisted of four primary tasks: commercial demonstrations, property database development, alloy development and optimization and evaluation of as-cast properties.

Alumina Forming Ausenitic Steel↗

Novel Modified Optical Fibers for High Temperature In-Situ Miniaturized Gas Sensors in Advanced Fossil Energy Systems

This report covers the technical progress on the program “Novel Modified Optical Fibers for High Temperature In-Situ Miniaturized Gas Sensors in Advanced Fossil Energy Systems”, funded by the National Energy Technology Laboratory of the U.S. Department of Energy, and performed by the Materials Science & Engineering and Electrical & Computer Engineering Departments at Virginia Tech, and summarizes technical progress from July 1st, 2005 –June 30th, 2014. The objective of this program was to develop novel fiber materials for high temperature gas sensors based on evanescent wave absorption in optical fibers. This project focused on two primary areas: the study of a sapphire photonic crystal fiber (SPCF) for operation at high temperature and long wavelengths, and a porous glass based fiber optic sensor for gas detection. The sapphire component of the project focused on the development of a sapphire photonic crystal fiber, modeling of the new structures, fabrication of the optimal structure, development of a long wavelength interrogation system, testing of the optical properties, and gas and temperature testing of the final sensor. The fabrication of the 6 rod SPCF gap bundle (diameter of 70μm) with a hollow core was successfully constructed with lead-in and lead-out 50μm diameter fiber along with transmission and gas detection testing. Testing of the sapphire photonic crystal fiber sensor capabilities with the developed long wavelength optical system showed the ability to detect CO 2 at or below 1000ppm at temperatures up to 1000°C. Work on the porous glass sensor focused on the development of a porous clad solid core optical fiber, a hollow core waveguide, gas detection capabilities at room and high temperature, simultaneous gas species detection, suitable joining technologies for the lead-in and lead-out fibers and the porous sensor, sensor system sensitivity improvement, signal processing improvement, relationship between pore structure and fiber geometry to optical properties, and the development of a sensor packaging prototype for laboratory testing. Analysis and experiments determined that a bonding technique using a CO 2 laser is the most suitable joining technique. Pore morphology alteration showed that transmission improved with increasing annealing temperature (producing smaller pores), while the sensor response time increased and the mechanical strength decreased with increasing annealing temperature. Software was developed for data acquisition and signal processing to collect and interpret spectral gas absorption data. Gas detection on porous glass sensors was completed and the detection limit was evaluated using acetylene and was found to be around 1- 200ppm. A complete materials package for porous glass sensors was manufactured for testing.

36 MATERIALS SCIENCE↗

Oxy-Combustion System Process Optimization

The overall objective of this work is to develop a new chemical absorbent-based, high pressure, CO 2 purification system to remove the residual oxygen that currently contaminates the recovered CO 2 , and to optimize the Pressurized Oxy-Combustion (POxC) process to minimize the Cost of Electricity (COE) generated in this advanced combustion process. TDA developed and validated the performance of the oxygen removal system for CO 2 purification. In collaboration with the Advanced Power & Energy Program (APEP) of University of California, Irvine (UCI), we optimized the POxC process, including thermal management, heat integration, and power cycle optimization using process design and modeling supported with Aspen Plus® process simulations. The techno-economic analysis results indicate that the pressurized oxycombustion coal power plant with Ion-transport membrane (ITM) air separation unit (ASU) (Case 2 – 30.55%) does not show an advantage over a cryogenic ASU (Case 1 – 31.24%) while TDA’s sorption-based ASU (Case 4 - 32.61%) shows a significant advantage over the cryogenic ASU (Case 1 – 331.24%). The specific plant costs show a wide range with a low of $2544/kW for Case 11C (TDA ASU, co-sequestering the SO x , and ultra-supercritical steam cycle) to a high of $2975/kW for Case 12A (cryogenic ASU and sCO 2 cycle). In general, the ITM ASU based cases have lower specific plant costs than the corresponding cryogenic ASU based cases while the TDA ASU based cases show the lowest specific plant costs. The main reason for lowering these costs is the higher overall plant thermal efficiency which decreases the plant cost on a $ per kW basis. Next comparing the cases with different power cycle working fluid conditions in terms of temperature and pressure while all utilizing steam, similar trends as the plant costs may be observed. However, with the supercritical CO 2 (sCO 2 ) cycle, the increase in thermal efficiency of the sCO 2 cycle was not able to offset its increase in plant cost making the plant costs higher than those of the corresponding steam cycle cases. The Cost of Electricity (COE) again shows similar trends as the specific plant costs. The COE for Case 11C at $110.1/MWh is also the lowest, but among all cases that do not co-sequester the SO x , Case 12C (TDA ASU and sCO 2 cycle) has the lowest COE at $\$$117.5/MWh while the highest is for Case 8A (cryogenic ASU and supercritical steam cycle) at $130.4/MWh.

20 FOSSIL-FUELED POWER PLANTS↗

Preliminary Experimental Results in Support of the Development of EPP and SMT Design Methods and Viscoplastic Model for A709

The ASME code qualification effort for Alloy 709 (A709) is currently underway to qualify it for Class A construction in the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code, Section III, Division 5. The United States (U.S.) Department of Energy (DOE) national laboratories are collaborating in the advanced materials development initiative to investigate the mechanical performance of A709 in support of its code qualification. As part of the A709 code qualification effort, this report summarizes ORNL’s initial experimental findings that support the integration of A709 into the elastic-perfectly plastic (EPP) strain limits code case. It also covers thermomechanical fatigue testing conducted to develop viscoelastic material models, along with the preliminary results of creep-fatigue experiments at 816°C using the Simplified Model Test (SMT) method.

36 MATERIALS SCIENCE↗