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DOE OSTI2024

Alternatives to MARVEL Power Conversion – Comparison of Stirling Engine Thermal Efficiency and Design to other Power Conversion Cycles

The Microreactor Applications, Research, Validation, and Evaluation (MARVEL) Reactor is a small liquid-metal thermal reactor that will be built at the Idaho National Laboratory to demonstrate design and operating processes for microreactors, microgrid integration, and process heat applications. Power conversion in the MARVEL design is provided by Stirling engines, which have disadvantages in nuclear environments. Compared to Stirling engine performance, some alternative power cycles can increase power production when coupled to a liquid-metal thermal reactor In this paper, the thermal efficiency of MARVEL’s power production with Stirling engines is compared to the thermal efficiency of power production with MARVEL and alternative power cycles. Those cycles include a superheated Rankine cycle, open and closed Brayton cycles, and a supercritical carbon dioxide cycle. All cycles (except the Stirling engines) were modeled with an intermediate helium loop to meet MARVEL’s principal design criteria. All models are simple designs with conservative assumptions for consistent comparison. Detailed optimization will depend largely on reactor location and application, and the relative merit of each cycle is discussed for different environmental conditions. The study informs significant early decisions on power cycle design and economic

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

NASA NTRSDate not supplied

Wildfire Emergency Response Hazard Extraction and Analysis of Trends (HEAT) through Natural Language Processing and Time Series

A methodology for Hazard Extraction and Analysis of Trends (HEAT) is proposed and conducted on a data set of wildfire incident response forms, known as ICS-209-PLUS.The HEAT processes: (1) extract a set of hazards from a data set, (2) calculate hazard-relevant metrics in a primary analysis, (3) analyze trends over time in metrics using timeseries, and (4) examine potential explanations for metric trends using a secondary analysis. Hazards are extracted from narrative data in the ICS-209-PLUS based on a framework previously developed by the authors, using natural language processing. Metrics examined for each hazard include operational time to occurrence, rate of occurrence, frequency, and severity. Primary results include a taxonomy of hazards present in the data set with relevant quantitative metrics. The most frequent hazards identified are environmental and include hazardous terrain. Most hazards occur on average between 35-55% containment. Incidents with hazards tend to have a higher average severity score when compared to the average score for all incidents. Time series of the metrics and relevant predictors, including fire characteristics, fire intensity, and operations, are created to facilitate further analysis. Secondary results used to determine which factors best predict hazard frequency include a correlation matrix and regression analysis. These findings are relevant to safety for current, as well as emerging wildfire operations, and are an exploratory first step in developing historical data-driven risk assessment models.

Sequoia R. Andrade↗

NASA NTRS1979

Heat pipe cooling of power processing magnetics

A heat pipe cooled transformer and input filter were developed for the 2.4 kW beam supply of a 30 cm ion thruster system. This development yielded a mass reduction of 40% (1.76 kg) and lower mean winding temperature (20 C lower). While these improvements are significant, preliminary designs predict even greater benefits to be realized at higher power. The design details are presented along with the results of thermal vacuum operation and the component performance in a 3 kW breadboard power processor.

Hansen, I. G.↗

DOE OSTI2024

Economic assessment of a multistage surface-heated vacuum membrane distillation process for the treatment of hypersaline produced water

Here, the treatment and disposal of hypersaline produced water remains a challenge, particularly for oil and gas producers in the Permian basin where production wells generate significant amounts of wastewater, and the traditional method of injecting wastewater into disposal wells is coming under increasing scrutiny. Here we investigate the viability of using solar energy to power a multi-stage, surface heated, vacuum membrane distillation (SHVMD) with energy recovery to treat hypersaline produced wastewater from Midland, Texas. Membrane distillation is a process that can desalinate waters with high total dissolved solids concentration, and when incorporated into a system with surface heating and energy recovery can achieve high water recovery rates. Model results show that a 6-stage SHVMD system with a 54.4 % water recovery rate and a gained output ratio (GOR) of 3.28 has the potential to be economically viable when used to treat hypersaline produced water in the Permian basin. Assuming energy costs of $\$0.03$/kWh thermal and $\$0.12$kWh electric , we estimate a project net present value (NPV) of $\$225,525$ and an internal rate of return (IRR) of 13.5 % when an air cooled condensor is used to cool the distillate and a NPV of $\$570,791$ and IRR of 24.52 % when a liquid coooling source is available.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2025

Particle Handling in Particle-Based Pumped Thermal Energy Storage

A particle-based pumped thermal electricity storage system stores high-temperature heat (~1000 degrees C) in low-cost silica sand and generates power through an efficient power cycle. Central to this system is a counterflow direct-contact gas/particle fluidized-bed heat exchanger, which can significantly improve the heat exchange process due to the large heat transfer surface area of particles. To showcase a lab-scale 10- to 20-kWe heat exchange process with particles heating up to 300 degrees C, a comprehensive hydrodynamic analysis of the fluidization condition inside the heat exchanger was conducted. The heat exchanger was designed to target for heat exchange process of 10-20 kW and accommodate an air mass flow rate of 0.3-0.7 kg/s. The fluidization condition was set to maintain stable bubbling fluidization, thereby maximizing the particle-to-air heat transfer. An air distributor was designed to equally distribute air over the bed, which can avoid defluidized zones in the heat exchanger. Additionally, particle handling systems including L-valves, screw conveyors, and pneumatic conveyors were developed for the prototype heat exchanger, efficiently conveying high-temperature particles at 0.2-0.5 kg/s. This work lays the foundation for scaling up the system and integrating it into larger energy storage applications, demonstrating its potential for efficient, high-temperature thermal energy storage and power generation.

25 ENERGY STORAGE↗

DOE OSTI2015

ENTROPY VS. ENERGY WAVEFORM PROCESSING: A COMPARISON ON THE HEAT EQUATION

Virtually all modern imaging devices function by collecting either electromagnetic or acoustic backscattered waves and using the energy carried by these waves to determine pixel values that build up what is basically an ”energy” picture. However, waves also carry ”informa- tion” that also may be used to compute the pixel values in an image. We have employed several measures of information, all of which are based on different forms of entropy. Numerous published studies have demonstrated the advantages of entropy, or “information imaging”, over conventional methods for materials characterization and medical imaging. Similar results also have been obtained with microwaves. The most sensitive information measure appears to be the joint entropy of the backscattered wave and a reference signal. A typical study is comprised of repeated acquisition of backscattered waves from a specimen that is changing slowing with acquisition time or location. The sensitivity of repeated experimental observations of such a slowly changing quantity may be defined as the mean variation (i.e., observed change) divided by mean variance (i.e., observed noise). We compute the sensitivity for joint entropy and signal energy measurements assuming that noise is Gaussian and using Wiener integration to compute the required mean values and variances. These can be written as solutions to the Heat equation, which permits estimation of their magnitudes. There always exists a reference such that joint entropy has larger variation and smaller variance than the corresponding quantities for signal energy, matching observations of several studies. Moreover, a general prescription for finding an “optimal” reference for the joint entropy emerges, which also has been validated in several studies.

Entropy↗

DOE OSTI2013

Strategic Coupling of Advanced Induction Heating with Magnetic Field Processing Technologies Provides Innovative Solutions for Elevated Industries Demands

Industry s relentless pursuit of product performance improvements is now challenging the capability of available/existing Thermal processing technologies, i.e., Heat Treating. In fact, the EPA-mandated requirement for light-weighting vehicles underscores the urgent US need for achieving higher product strength improvements.

Ludtka, Mackiewicz-Ludtka↗

DOE OSTI2025

Quench process modeling & simulation in the heat-treatment of critical aerospace components

To manufacture light-weight, advanced metal alloy components for gas turbine engines, quench heat-treatment processes are typically used. By quenching the component from elevated temperatures, the alloy sometimes undergoes a solid-state phase transformation which produces special microstructures with the required, enhanced mechanical properties. However, the quenching can also lead to cracks forming in the component. Addressing the quench cracking problems adds a significant burden to the cost, schedule, and energy demand of manufacture. Currently, optimizing the quench process to mitigate or avoid the cracking is performed largely by trial-and-error, relying heavily on costly experimental (thermocouple)trials to understand the local thermal gradients which cause the cracks to form. In this first part (Phase 1) of the work, high-performance computing is employed to establish the ability of modern CFD (computational fluid dynamics) to alleviate or wholly replace the experimental quenching trials by virtual testing. A Baseline CFD model is defined and its accuracy established to be comparable to(and which usually exceeds) the accuracy of existing HTC (heat-transfer coefficient) based simulation methods of quenching. As a first-principles based approach, “calibration” of the Baseline CFD model is independent of the quench process itself, but instead relies on the accuracy of the underlying (modeled),generic two-phase fluid processes which cannot be currently resolved by CFD for large, industrial-scale cases. A novel, high-fidelity DNS capability has been developed and verified to examine and further improve upon the mean-field closure submodels on which the Baseline CFD approach is based.1

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2024

Quench process modeling & simulation in the heat-treatment of critical aerospace components

To manufacture light-weight, advanced metal alloy components for gas turbine engines, quench heat-treatment processes are typically used. By quenching the component from elevated tempera-tures, the alloy sometimes undergoes a solid-state phase transformation which produces special microstructures with the required, enhanced mechanical properties. However, the quenching can also lead to cracks forming in the component. Addressing the quench cracking problems adds a significant burden to the cost, schedule, and energy demand of manufacture. Currently, optimizing the quench process to mitigate or avoid the cracking is performed largely by trial-and-error, relying heavily on costly experimental (thermocouple) trials to understand the local thermal gradients which cause the cracks to form. In this first part (Phase 1) of the work, high-performance computing is employed to establish the ability of modern CFD (computational fluid dynamics) to alleviate or wholly replace the experimental quenching trials by virtual testing. A baseline CFD model is defined and its accuracy established to be comparable to (and which usually exceeds) the accuracy of existing HTC (heat-transfer correlation) based simulation methods of quenching. As a first-principles based approach, “calibration” of the Baseline CFD model is independent of the quench process itself, but instead relies on the accuracy of the underlying (modeled), generic two-phase fluid processes which cannot be currently resolved by CFD for large, industrial-scale cases. A novel, high-fidelity DNS capability has been developed and verified to examine and further improve upon the mean-field closure submodels on which the Baseline CFD approach is based.

36 MATERIALS SCIENCE↗

DOE OSTI2023

A Comparative Evaluation and Selection of High-Temperature Heat Exchangers for Application to Integrated Energy Systems

The following report aims to create a refined and well-structured method for comparatively evaluating heat exchanger technologies for integrated energy systems that caters customers’ specific needs while meeting engineering requirements. For the evaluation, this study elevates previous evaluation metrics, enhances the knowledge base via literature and market surveys, and identifies the figures of merit with robust rationales to enhance the quality of decisions made throughout the proposed heat exchanger evaluation process. The heat exchanger designs evaluated as part of the case study are shell and tube heat exchangers, printed circuit heat exchangers, plate heat exchangers, spiral heat exchangers, and heat pipe heat exchangers. The information presented in this report is meant for industries interested in making a preliminary screening process to identify the most suitable heat exchanger design for their application of interest.

42 ENGINEERING↗

DOE OSTI2023

A Comparative Evaluation and Selection of High-Temperature Heat Exchangers for Application to Integrated Energy Systems

42 - ENGINEERING↗

DOE OSTI2018

Comparative modelling of the coupled thermal–hydraulic-mechanical (THM) processes in a heated bentonite pellet column with hydration

For the deep geological disposal of high-level radioactive waste in argillaceous rocks, the heat production of the waste is an important driver for thermal–hydraulic-mechanical (THM)-coupled processes. These THM processes influence the properties and conditions of the near field that in many repository designs contains bentonite as a clay buffer. One task in the DECOVALEX-2015 (DEvelopment of COupled models and their VALidation against Experiments) project was the modelling of a heated bentonite column (Villar et al. in Long-term THM tests reports: THM cells for the HE-E test: update of results until February 2014. Deliverable-no: D2.2-7.3. CIEMAT Technical Report IEMAT/DMA/2G210/03/2014, 2014) in preparation for the in situ heater experiment HE-E at the underground rock laboratory Mont Terri. DECOVALEX is an international cooperative project that focuses on the development and validation of mathematical models for simulating such coupled processes associated with disposal in deep geological repositories. Eight modelling teams developed their own THM-coupled models for the bentonite column experiment, using six different simulation codes. Each of the teams individually calibrated the THM parameters for the bentonite material. The eight resulting parameter sets agree well and allow a satisfactory reproduction of the TH measurements by all models. The modelling results for the evolution of temperature and relative humidity over time at three sensors in the bentonite column are in good agreement between the teams and with the measured data. Also, changes of the temperature due to modifications of the insulation and the adjustment of the heating power during the course of the experiment are well reproduced. The models were thus able to reproduce the main physical processes of the experiment, both for vapour-dominated diffusion during the heating phase and combined liquid and vapour transport during a subsequent heating and hydration phase. Lastly, based on the parameter sets, the teams predict a penetration of the water infiltration front in the 48-cm column filled with bentonite pellets to a depth between 25 and 35 cm over the 15,000 h (i.e. over 20 months) of the hydration phase of the experiment.

58 GEOSCIENCES↗

DOE OSTI2019

Combined Sorbent/WGS-based CO 2 Capture Process with Integrated Heat Management for IGCC Systems

Southern Research has developed a combined CO 2 capture water-gas shift (WGS) process for integrated gasification combined cycle (IGCC) applications. A highly efficient regenerable magnesium based sorbent was prepared to remove CO 2 . It offers high and stable CO 2 capacity with minimum requirement for temperature and pressure swings. Under optimized conditions, the sorbents achieved up to 8 mmol/g of CO 2 working capacity and remained stable over 500 cycles of adsorption and regeneration. The selected WGS process achieved 96% CO per pass conversion and remained isothermal during the test duration that lasted over 500 cycles. The approach showed potential to reduce cost of electricity (COE) compared to the baseline carbon capture approaches. The process is for bench-scale and pilot development. In a commercial embodiment, syngas from the gasifier is cooled to warm gas conditions. It then enters the CO 2 sorbent-shift reactor that uses an efficient MgO-based CO 2 sorbent and a commercial catalyst to shift the CO to CO 2 and capture 90% + of the carbon. Using a dual-bed arrangement, the sorbent is regenerated periodically by a combination of pressure and temperature swing to maintain steady state conditions and produce a 95+ % CO 2 stream for sequestration. The hydrogen rich syngas is sent to the IGCC for power production. In addition to consolidating CO 2 capture with WGS, the proposed process reduces parasitic energy losses by operating at warm gas temperatures and reduces parasitic plant load (i.e., steam and auxiliary power) by reducing energy required for regeneration. The project consisted of 3 budget periods (BP) of laboratory-scale research and testing with go/no-go decisions after BP-1 and BP-2. In the 12 month BP-1, it was shown show that one promising sorbent maintained the required CO 2 capacity and durability of >1.5 mmol/g over 100 cycles. Also based on sorbent and WGS experiments in separate reactors and combined reactor modeling, it was shown that the process had the potential to capture 90% of the CO 2 at a lower than conventional amine-based approach. In the 18 month BP-2, a lab scale combined sorbent/WGS reactor system was built, commissioned, and tested with the promising sorbent from BP-1. 90% carbon capture was demonstrated over 100 cycles and it was shown that the process continued to have potential to capture 90% of the carbon at a cost that was less than the conventional amine-based approach. In the 6 month BP-3, a long term test was conducted using the best SR sorbent. The required durability of > 2 mmol/g was demonstrated after 500 cycles. Also, 90% carbon capture and 96% CO conversion was maintained over 1000 cycles. A technical and economic feasibility study was carried out to compare the proposed pre-combustion approach to a gasification plant employing a conventional pre-combustion approach and a conventional pulverized caol (PC) plant employing a conventional post combustion CO 2 capture approach.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2012

High Magnetic Field Processing - A Heat-Free Heat Treating Method

The High and Thermal Magnetic Processing/Electro-magnetic Acoustic Transducer (HTMP/EMAT) technology has been shown to be an enabling disruptive materials processing technology, that can achieve significant improvements in microstructure and consequently material performance beyond that achievable through conventional processing, and will lead to the next generation of advanced performance structural and functional materials. HTMP exposure increased the reaction kinetics enabling refinement of microstructural features such as finer martensite lath size, and finer, more copious, homogeneous dispersions of strengthening carbides leading to combined strength and toughness improvements in bainitic steels. When induction heating is applied in a high magnetic field environment, the induction heating coil is configured so that high intensity acoustic/ultrasonic treatment occurs naturally. The configuration results in a highly effective electromagnetic acoustical transducer (EMAT).

Electron Microscopy↗

NASA NTRS1963

CALCULATED RESULTS FOR THE TRANSIENT HEATING AND MELTING PROCESS OF GLASS SHIELDS WITH VARIOUS MATERIAL PROPERTIES AT THE STAGNATION POINT OF A RE-ENTERING ICBM

Calculated results for transient heating and melting of glass shield at stagnation point of reentering icbm

SHIELDING↗

DOE OSTI2012

West Village Community: Quality Management Processes and Preliminary Heat Pump Water Heater Performance

West Village, a multiuse project underway at the University of California Davis, represents a groundbreaking sustainable community that incorporates energy efficiency measures and on-site renewable generation to achieve community-level goals of ultra high efficiency. The project, when complete, will provide housing for students, faculty, and staff, and maintain a vision to minimize the community’s environmental impact by reducing building energy use, providing on-site renewable energy generation, and encouraging alternative forms of transportation. The focus of this research concerns the 192 student apartments completed in 2011 under Phase I of the West Village multi-year project. The developer implemented numerous aggressive energy efficiency measures that are estimated to achieve 37% source energy savings over the Building America Benchmark. There are two primary objectives of this research. The first is to evaluate performance and efficiency of central heat pump water heaters for domestic water heating in ultra-efficient buildings. The second is to evaluate the effectiveness of quality assurance and quality control processes in ensuring proper system startup and operation and documenting compliance with efficiency programs. This research additionally recommends measures to promote successful implementation of quality processes in large-scale, high performance communities.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2015

r-PROCESS LANTHANIDE PRODUCTION AND HEATING RATES IN KILONOVAE

r-process nucleosynthesis in material ejected during neutron star mergers may lead to radioactively powered transients called kilonovae. The timescale and peak luminosity of these transients depend on the composition of the ejecta, which determines the local heating rate from nuclear decays and the opacity. Kasen et al. and Tanaka and Hotokezaka pointed out that lanthanides can drastically increase the opacity in these outflows. We use the new general-purpose nuclear reaction network SkyNet to carry out a parameter study of r-process nucleosynthesis for a range of initial electron fractions Y{sub e}, initial specific entropies s, and expansion timescales τ. We find that the ejecta is lanthanide-free for Y{sub e} ≳ 0.22−0.30, depending on s and τ. The heating rate is insensitive to s and τ, but certain, larger values of Y{sub e} lead to reduced heating rates, due to individual nuclides dominating the heating. We calculate approximate light curves with a simplified gray radiative transport scheme. The light curves peak at about a day (week) in the lanthanide-free (-rich) cases. The heating rate does not change much as the ejecta becomes lanthanide-free with increasing Y{sub e}, but the light-curve peak becomes about an order of magnitude brighter because it peaks much earlier when the heating rate is larger. We also provide parametric fits for the heating rates between 0.1 and 100 days, and we provide a simple fit in Y{sub e}, s, and τ to estimate whether or not the ejecta is lanthanide-rich.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2018

Effects of Heating and Quenching Processing Parameters on Phase Transformation of 55CrMo Steel

Microstructure and mechanical properties after induction hardening have a significant effect on the wear resistance performance and lifetime of 55CrMo steel ball screw. In the paper, the dilatometric curves were recorded at the different heating rate by a Gleeble-1500D thermo-mechanical simulator to determine the effect of heating rate on the austenitizing temperature of 55CrMo steel. Heat treatment of some specimens was performed by the Gleeble-1500D thermal simulator at the different heating temperature, holding time and cooling rate to investigate the effect of induction hardening parameters on the phase transformation, microstructure and microhardness of 55CrMo steel. Microstructure of specimen was analyzed using an optical microscope and a scanning electron microscope. Volume fraction of retained austenite was measured using an x-ray diffractometer. The mechanical properties were evaluated by a microhardness tester. The results show that the austenitizing temperature of 55CrMo steel increases with the increasing heating rate. Increasing the heating temperature, holding time and cooling rate of specimen is helpful in obtaining a uniform cryptocrystalline martensite. Volume fraction of retained austenite is less as the heating temperature is in the range of 900-950 °C. In the induction hardening of 55CrMo steel, the heating temperature should be in the range of 900-1000 °C.

36 MATERIALS SCIENCE↗