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DOE OSTI2022

High Temperature, High Pressure Stability of Aqueous Foams for Potential Application in Enhanced Geothermal System (EGS)

Enhanced Geothermal Systems (EGS) are typically constructed by injecting high-pressure water into deep hot dry rocks (HDR) under carefully controlled conditions to create new or re-open existing fractures, which usually uses an immense quantity of water. In lieu, a more sustainable technique is to utilize aqueous foams as fracturing fluid to reduce water consumption and waste-water treatments of conventional hydraulic fracturing. Although foam-based fracturing has shown promising results in oil and gas industries, its feasibility is not demonstrated in EGS conditions that usually involve high temperature and high pressures. One potential barrier of utilizing foams in EGS applications is that foams are thermodynamically unstable and will become more unstable with increasing temperature due to liquid drainage, bubble coarsening, and coalescence. This work focuses on evaluation of the stability of selected aqueous foams under high-temperature and high-pressure conditions. Specifically, foams generated with surfactant alfa olefin sulfonate (AOS) were studied at temperature up to 200oC, while the pressure ranged between 100 psi and 1000 psi. The effect of additional stabilizing agents was also examined, including guar gum, bentonite clay, borate salt crosslinker, silicon dioxide nanoparticles (SiO2), and graphene oxide (GO) dispersion. Results showed that the stabilizing agents can enhance the foam thermal stability. Foams made with AOS and the borate salt crosslinker exhibited the longest half-life of 20 min at 200°C when the pressure was at 1000 psi. Data fitting showed that foam stability decreased exponentially as temperature increased. On the other hand, pressure increased the foam half-life which followed a power model. This study indicates that it may be possible to obtain highly stable foams at high-temperature and high-pressure conditions with appropriate stabilizing agents.

Thakore, Viren↗

DOE OSTI2021

A techno-economic framework for comparing conventionally and additively manufactured parts for geothermal applications

Geothermal reservoir characterization, construction, and operations are technology-intensive activities that contribute significantly to the cost of delivering renewable electricity. The technologies involved, such as downhole tools and drilling equipment, are similar to those used in oil and gas exploration and production must often be adapted for use in the corrosive, high-temperature geothermal reservoir environment. Low production volume of geothermal tools presents a major challenge in meeting the industry's technology needs. Production of specialized tools for geothermal subsurface applications is often cost-prohibitive. Reduced inventory of subsurface well construction, characterization, and production tools causes geothermal reservoir development efficiency and sophistication to lag behind that of the oil and gas industry. Advances in additive manufacturing provide opportunities to advance geothermal technology while reducing lead time and costs associated with production of low-volume, complex parts. Additionally, this paper performs an initial techno-economic analysis comparing the cost of conventional production techniques and additive manufacturing for geothermal downhole applications. An analysis of representative downhole tools is used to create a framework for estimating fabrication costs of subtractive and additive techniques, including post-print machining required to meet final tolerances. The framework is used to explore several manufacturing scenarios and identify the dominant factors driving manufacturing time and cost. The current feasibility of additive manufacturing for geothermal downhole tool applications is assessed and issues for future development to better meet the needs of the geothermal industry are identified.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Investigations on the multiple-sector hard-copper X-band accelerating structures

The development of advanced, high gradient accelerating structures is one of the leading activity of the particle accelerator community. In the technological research of new construction methods for these devices, high-power testing is a critical step for the verification of their viability. Recent experiments showed that accelerating cavities made out of hard copper, fabricated without high-temperature processes, can achieve better performance as compared with soft copper ones. Recently, we have built cavities using Tungsten Inert Gas welding and the high-power experiments confirmed that this joining process is a robust and low-cost alternative to brazing or diffusion bonding. This is a good solution for high-gradient operation, with a gradient of about 150 MV/m in X-band, at a breakdown rate of 10 -3 /pulse/meter using a shaped RF pulse with a 150 ns flat part. We continue the design, construction and high power tests of three-cells standing-wave X-band accelerating cavities fabricated with a split-open geometry, made of hard copper and vacuum-sealed by welding. Our aim is the fabrication of accelerating structures made out of hard copper alloys by using innovative cost-effective technologies. Moreover, our method of multiple-sector structures opens the way to new technological approaches and design methods, for example providing the possibility of placing dampers of the parasitic higher-order modes. Such structures with dampers allow for acceleration of multi-bunch beams, both in standing and in travelling-wave accelerating modality. Here, this paper describes the design of two cavities made of multiple sectors that were fabricated at the Italian Institute for Nuclear Physics in Frascati, Italy (INFN-LNF), assembled by means of clamping and then joined with the Tungsten Inert Gas welding in order to preserve the hardness of the metal. These are three-cell standing-wave X-band accelerating cavities, to be operated in the π-mode. We report the low-power RF tests of the first one, made of two halves, and the RF design of the second one, made of four quadrants. Both structures were built for high-gradient tests at SLAC National Accelerator Laboratory.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2024

Intensified biogas to liquid (IBGTL) Process: Experimental validation and modeling analysis

The Intensified Biogas to Liquid (IBGTL) process aims to overcome traditional economy-of-scale barriers in biogas-to-liquid fuel production by integrating bi-reforming and Fischer-Tropsch synthesis (FTS) in a single IBGTL reactor. This reactor operates at uniform pressure with different optimized temperatures across two zones for efficient conversion, utilizing multifunctional bi-reforming catalysts and high-temperature FTS catalysts. Bench scale experiments were carried out using landfill gas (LFG) in a single pass process, and the yield data from these experiments were fed into process scale-up design and techno-economic analysis (TEA) across four scenarios: (1) a single pass process, (2) a process with material recycling, (3) a process with liquefied petroleum gas (LPG) co-product recovery, and (4) a process with electricity generation from the fuel gas produced. TEA identified Scenario 2 as the most cost-effective, achieving a Minimum Fuel Selling Price (MFSP) of $\$4.59$ per gallon, competitive with the current national diesel price of $\$4.7$ per gallon. However, comparison with the conventional two-reactor system highlights the need for catalyst performance improvements. Sensitivity analysis emphasized the importance of manufacturing cost, liquid fuel yield, and biogas flow rate. Further analysis determined that the IBGTL process must achieve a diesel mass yield beyond 11.7% to surpass the economic viability of the conventional TriFTS (Tri-reforming followed by Fischer-Tropsch Synthesis) process. If the IBGTL process attains the TriFTS yield of up to 17%, the resulting MFSP could be approximately 31% lower than the current TriFTS MFSP. Furthermore, renewable energy credits and carbon credits can further enhance the economic viability of BGTL processes.

09 BIOMASS FUELS↗

DOE OSTI2022

Stainless and carbon steel corrosion in aqueous piperazine at absorber and water wash conditions

Corrosion of carbon steel (C1010) and stainless steels (304, 316L, 430) was measured at absorber and water wash conditions at the bench scale. Corrosion rate decreases with increasing concentration of piperazine (PZ). With more than 0.003 m PZ in solution, carbon steel has acceptable corrosion performance. Corrosion of carbon steel increases with increasing partial pressure of CO2, suggesting loading is another dominant parameter. The effect is more significant for dilute PZ; therefore, untreated flue gas with high CO2 content should be avoided in the water wash. Temperature has a less significant effect than PZ concentration and loading. Carbon steel corrosion increases with increasing flow velocity at both absorber and water wash conditions

Liu, Ching-Ting↗

DOE OSTI2020

Crystallographic Orientation Dependence of Mechanical Responses of FeCrAl Micropillars

Iron-chromium-aluminum (FeCrAl) alloys are used in automobile exhaust gas purifying systems and nuclear reactors due to its superior high-temperature oxidation and excellent corrosion resistance. Single-phase FeCrAl alloys with a body centered cubic structure plastically deform through dislocation slips at room temperature. Here, we investigated the orientation dependence of mechanical responses of FeCrAl alloy through testing single-crystal and bi-crystal micropillars in a scanning electron microscopy at room temperature. Single-crystal micropillars were fabricated with specific orientations which favor the activity of single slip system or two slip systems or multiple slip systems. The strain hardening rate and flow strength increase with increasing the number of activated slip system in micropillars. Bi-crystal micropillars with respect to the continuity of slip systems across grain boundary were fabricated to study the effect of grain boundary on slip transmission. The high geometrical compatibility factor corresponds to a high flow strength and strain hardening rate. Experimental results provide insight into understanding mechanical response of FeCrAl alloy and developing the mechanisms-based constitutive laws for FeCrAl polycrystalline aggregates.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Hybrid solar system

A hybrid solar system including a hybrid solar collector using non-imaging optics and photovoltaic components and a heat transfer and storage system in thermal communication with the hybrid solar collector, the heat transfer and storage system using particle laden gas as thermal media to simultaneously generate and store electricity and high temperature dispatchable heat.

14 SOLAR ENERGY↗

DOE OSTI2021

Development of dispensing hardware for safe fueling of heavy duty vehicles

The development of safe dispensing equipment for the fueling of heavy duty (HD) vehicles is critical to the expansion of this newly and quickly expanding market. This paper discusses the development of a HD dispenser and nozzles assembly (nozzle, hose, breakaway) for these new, larger vehicles where flow rates are more than double compared to light duty (LD) vehicles. This equipment must operate at nominal pressures of 700 bar, -40o C gas temperature, and average flow rate of 5-10 kg/min at a high throughput commercial hydrogen fueling station without leaking hydrogen. The project surveyed HD vehicle manufacturers, station developers, and component suppliers to determine the basic specifications of the dispensing equipment and nozzle assembly. The team also examined existing codes and standards to determine necessary changes to accommodate HD components. From this information, the team developed a set of specifications which will be used to design the dispensing equipment. In order to meet these goals, the team performed computational fluid dynamic, pressure modelling, and temperature analysis in order to determine the necessary parameters to meet existing safety standards modified for HD fueling. The team also considered user, operational, and maintenance requirements, such as freeze lock which has been an issue which prevents the removal of the nozzle from LD vehicles. The team also performed a failure mode and effects analysis (FMEA) to identify the possible failures in the design. The dispenser and nozzle assembly will be tested separately, and then installed on an innovative, HD fueling station which will use a HD vehicle simulator to test the entire system.

08 HYDROGEN↗

DOE OSTI2023

Fluid structural interaction simulation of the MP-1 plate performance irradiated in the advanced test reactor

Due to the high neutron fluxes they generate and increased heat transfer performance, plate type fuels are used in the U.S. high-performance research reactors. During irradiation, a significant amount of fission energy (i.e., ~200 MeV per atom) is released by the U-235 chain reaction that is carried away by the coolant. Through thermal hydraulic analysis, the coolant’s heat transfer capability is investigated to ensure that the desired fuel temperature can be maintained. At high temperatures, the plate undergoes elastic/plastic deformation, creep, and swelling as a result of both the temperature gradients and the fission gas production within the fuel. These effects are studied via fuel performance analysis. When the plate deformation is small enough that the coolant flow remains relatively unchanged, conducting these two types of analyses independently will suffice. But at high fuel burnups, the swollen plates may encroach into the coolant channels that separate the fuel plates from each other and cause these channels to narrow. Large reductions in channel gap size imperil cooling performance, causing fuel temperatures to rise. Further, if the plate deformation is asymmetric, the fuel centerline will shift toward one side of the channel, causing an uneven reduction in coolability. In addition, a boehmite (oxide) layer will, over time, grow on the plate surface, further obstructing the heat transfer process. To precisely predict fuel temperatures/deformation, a complete coupled analysis that considers coolant flow, heat transfer, oxide growth, elastic/plastic deformation, creep, and swelling is needed; however, this type of analysis method is not available in the literature. To fill the gap, this research developed a fluid structure interaction (FSI) approach to the fuel plate analysis, then successfully applied it to the Mini-Plate (MP)-1 experiment, which was irradiated in the Advanced Test Reactor (ATR) for both one and two cycles. The complete analysis coupled STAR-CCM+, a computational fluid dynamic (CFD) software for calculating flow, with Abaqus, a finite element analysis code for calculating plate deformation. Improvements in the results were found when comparing the fully coupled analysis to the independently conducted analyses but they were not significant due to the miniature size of the plates and the relatively short irradiation time. In the future, the fully coupled approach presented herein will be applied to full-size fuel plates with longer irradiation cycles once additional experiments become available.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2020

High Temperature Erosion Modeling in Particle Based CSP Systems

1. Introduction. Wear and erosion damage of materials from solid particle and surface interactions is a major issue in various industries. Although more common in mining and oil and gas production, erosion is becoming a critical issue in renewable technologies as well such as particle based concentrated solar thermal power (CSP) systems. In particle based CSP systems, solid particles are used to absorb solar energy and as thermal storage. However, these particles may cause significant amount of wear to system components while through the system at high temperatures. This damage can be costly, and therefore, requires a greater understanding of solid particle erosion in CSP systems. Throughout the years, models and tools have been developed to predict and control erosion in industries such as oil and gas production. However, these erosion models and erosion prediction tools have been mainly developed based on erosion data for much higher velocities and lower temperatures, i.e. the operating conditions for which the existing models have been built are not pertinent to those expected in CSP system. It is known that erosion depends on many factors such as material properties, erodent particle properties, and particle impact speed and angle. However, the effect of temperature on erosion is not vastly investigated. In this work, a temperature-based correlation is introduced that will be used to modify the existing erosion models to predict erosion rates at velocities and temperatures relevant to Gen3 CSP systems. The existing models are first validated against erosion experiments run at low temperatures and low velocities. Subsequently, a temperature correction term is developed that can extend the existing models to high temperatures, based on the available experimental data showing the effect of temperature on impact erosion. 2. Erosion Models. Continuing sequence of impacts from solid particles on surfaces would result in loss of material due to mechanical interaction between solid surface and particles. Erosion equations have been developed to predict erosion under different conditions and erosion mechanism, including cutting and deformation erosion. These models are mainly either mechanistic, empirical, and semi-mechanistic models, when the latter combine the theory of the erosion mechanism and particle motion with the available experimental data. One of the first empirical correlation was introduced by American Petroleum Institute (API) Recommended Practice (RP) 14E [1]. This correlation was very conservative, and several improved empirical and semi-mechanistic equations were developed in the years following. More recently, the models introduced by Erosion/Corrosion Research Center (E/CRC) at the University of Tulsa and Arabnejad. et al. [2] are frequently used in the literature and industry, as they account for many parameters affecting erosion including particle impact speed and angle, material density and hardness, and particle size and shape. However, both these models were developed based on data at relatively high velocities and also do not take into account any mechanical changes in material associated with thermal cycling at high temperatures. 3. Erosion Prediction at High Temperatures. In this work, the accuracy of Arabnejad et al. model and E/CRC model is investigated to predict impact erosion at conditions relevant to Gen3 CSP systems. Two significant deviations expected in Gen3 systems compared to operating conditions used to build these models are particle impact velocities and system temperature. As a first step, the performance of these models was validated at low velocities and temperatures. Impact erosion experiments were conducted on SS316 coupons using HSP 40/70 ceramic particles. Assuming particle rate of 1 kg/s/m, 0.0254 m of particle curtain thickness, and particle velocity of 1.5 m/s in the system, an overall erosion of 0.59 mm/year was calculated. The experimental results were subsequently compared to those from computational simulations and erosion of 0.47 mm/year was obtained using the Arabnejad et al. model. The results indicated that the models work well at low velocities and low temperature conditions. To account for temperature effect, a mathematical correlation was developed using data published by DUCOM [3] for Inconel 600 eroded by alumina particles at high velocities. The correlation was applied to both Arabnejad et. al model and the E/CRC model. The prediction results from these modified models were within 20% of this experimental data. Predictions of of erosion by the modified E/CRC model at three different temperatures are made. Similar to the calculation at low temperature, a typical CSP system with 1 kg/s/m of particle flow rate per unit length of the particle curtain and a curtain thickness of 0.0254 m is assumed. The annual thickness loss calculations were run for different particle impact velocities, assuming a uniform particle impact area equal to the cross-sectional area of the curtain (particle-particle interactions and dispersion of particles are not considered in obtaining the results). It is observed that erosion increases exponentially as temperature increases. Furthermore, it is also noted that, erosion changes non-linearly with impact velocity. Currently, experiments are also being conducted to measure erosion of SS316 at 800 ºC with HSP 40/70 particles at low impact velocities. We expect to use the results from high temperature testing to further improve the temperature correlation function. Similar models are also being developed for abrasion erosion resulting from particle sliding along the surfaces as well as attrition from particle to particle and particle to surface interactions. References. [1] Institute, A. P. (1991). API Recommended Practice for Design and Installation of Offshore Production Platform Piping System, API RP 14E. [2] Arabnejad, H., Mansouri, A., Shirazi, S. A., and McLaury, B. S. (2015a). Development of mechanistic erosion equation for solid particles. Wear, 332–333, 1044–1050. http://doi.org/10.1016/j.wear.2015.01.031. [3] https://ducom.com/high-temperature-erosion-evaluating-sample-wear/

14 SOLAR ENERGY↗

DOE OSTI2021

Direct Chemical Vapor Deposition Synthesis of Porous Single-Layer Graphene Membranes with High Gas Permeances and Selectivities

Single-layer graphene containing molecular-sized in-plane pores is regarded as a promising membrane material for high-performance gas separations due to its atomic thickness and low gas transport resistance. However, typical etching-based pore generation methods cannot decouple pore nucleation and pore growth, resulting in a trade-off between high areal pore density and high selectivity. In contrast, intrinsic pores in graphene formed during chemical vapor deposition are not created by etching. Therefore, intrinsically porous graphene can exhibit high pore density while maintaining its gas selectivity. Here in this work, the density of intrinsic graphene pores is systematically controlled for the first time, while appropriate pore sizes for gas sieving are precisely maintained. As a result, single-layer graphene membranes with the highest H 2 /CH 4 separation performances recorded to date (H 2 permeance > 4000 GPU and H 2 /CH 4 selectivity > 2000) are fabricated by manipulating growth temperature, precursor concentration, and non-covalent decoration of the graphene surface. Moreover, it is identified that nanoscale molecular fouling of the graphene surface during gas separation where graphene pores are partially blocked by hydrocarbon contaminants under experimental conditions, controls both selectivity and temperature dependent permeance. Overall, the direct synthesis of porous single-layer graphene exploits its tremendous potential as high-performance gas-sieving membranes.

chemical vapor deposition↗

DOE OSTI2022

High-Temperature Ceramic-Carbonate Dual-Phase Membrane Reactor for Pre-combustion Carbon Dioxide Capture (Final Scientific/Technical Report)

Arizona State University, in collaboration with University of South Carolina, worked on a project aimed at development of a new high temperature, high pressure CO 2 perm-selective membrane reactor for water-gas-shift reaction (WGS) with simulated gasifier syngas to produce a high concentration H 2 stream with CO 2 capture. The membrane reactor is made of a CO 2 semi-permeable ceramic-carbonate dual-phase (CCDP) membrane with high CO 2 perm-selectivity/permeance and thermal/mechanical stability for application in WGS reaction. The objectives of this project were to (1) synthesize the chemically/thermally stable tubular CCDP membranes with CO 2 permeance and selectivity (with respect to H 2 , CO or H 2 O) larger than 6.5×10-7 mol/m2·s·Pa and 500, respectively; (2) establish CCDP membrane reactor setup and study high pressure CO 2 permeation and WGS reaction with CO 2 capture using the setup; and (3) identify conditions for WGS in the CCDP membrane reactor that produce CO 2 and H 2 streams with purity of >99% and >90% respectively at CO conversion >95% and overall carbon capture >90%. The work in this project included both membrane development and membrane reactor process study. The membrane development efforts were focused on investigating a H 2 S resistant and highly oxygen-ionic conducting metal oxide material and membrane for CO 2 separation, fabrication of tubular samaria-doped-ceria/molten-carbonate CCDP membrane with high mechanical strength, and experimental and modeling study of high-pressure CO 2 permeation of the CCDP membranes. Mathematical models were developed to describe WGS in the CCDP membrane reactor without a catalyst or packed with a commercial high temperature WGS catalyst. Experiments on WGS in the CCDP membrane reactor with the commercial WGS catalyst, guided by the model analysis, were performed to identify optimum conditions for achieving the CO conversion, carbon capture, and the purity of the H 2 and CO 2 streams mentioned above. At 30 atm feed pressure, 750°C operation temperature, space velocity of 250 h-1, and with steam sweep, a single-stage CCDP membrane reactor with average CO 2 permeation flux of 0.5 cm3(STP)/min.cm2 can achieve CO 2 conversion of 95% and overall carbon capture of 94%, and produce CO 2 and H 2 streams with dry-based purity of >99% and 92% respectively. The project also included process design and techno-economic analysis (TEA) for a CCDP membrane reactor process for WGS reaction with CO 2 capture for a 550 MW coal-fired IGCC power plant, and its comparison with the conventional fixed-bed reactor system for WGS with follow-up CO 2 capture by an amine absorption process. The target performance for the reactor for WGS with CO 2 capture includes CO conversion >95%, hydrogen stream purity >90%, CO 2 stream purity >95%, and total carbon capture >90%. The CCDP membrane developed in this project can achieve the performance target, without subsequent CO 2 capture process at the optimum conditions identified in this project. The outcome of the process design and TEA analysis shows that the membrane reactor for WGS with in-situ CO 2 capture has an operating cost about 40% lower than that for the conventional fixed-bed reactor with a separate amine absorption process for CO 2 capture. However, the capital cost of the membrane reactor process is about twice that of the conventional process because of the higher cost of the CCDP membrane. Modeling analysis shows that a membrane reactor using a CCDP membrane with higher CO 2 permeance (about three times the current value) can deliver the targeted performance for WGS reaction with CO 2 capture at a much higher space velocity and lower membrane surface area to catalyst volume ratio, leading to a smaller catalyst amount and/or membrane area and hence significantly reduced membrane reactor capital costs.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2020

Transcritical diffuse-interface hydrodynamics of propellants in high-pressure combustors of chemical propulsion systems

Rocket engines and high-power new generations of gas-turbine jet engines and diesel engines oftentimes involve the injection of one or more reactants at subcritical temperatures into combustor environments at high pressures, and more particularly at pressures higher than those corresponding to the critical points of the individual components of the mixture, which typically range from 13 to 50 bars for most propellants. This class of trajectories in the thermodynamic space has been traditionally referred to as transcritical. However, the fundamental understanding of fuel atomization, vaporization, mixing, and combustion processes at such high pressures remains elusive. In particular, whereas fuel sprays are relatively well characterized at normal pressures, analyses of dispersion of fuel in high-pressure combustors are hindered by the limited experimental diagnostics and theoretical formulations available. The description of the thermodynamics of hydrocarbon-fueled mixtures employed in chemical propulsion systems is complex and involves mixing-induced phenomena, including an elevation of the critical point whereby the coexistence region of the mixture extends up to pressures much larger than the critical pressures of the individual components. As a result, interfaces subject to surface-tension forces may persist in multicomponent systems despite the high pressures, and may give rise to unexpected spray-like atomization dynamics that are otherwise absent in monocomponent systems above their critical point. In this article, the current understanding of this phenomenon is reviewed within the context of propulsion systems fueled by heavy hydrocarbons. Emphasis is made on analytical descriptions at mesoscopic scales of interest for computational fluid dynamics. In particular, a set of modifications of the constitutive laws in the Navier–Stokes equations for multicomponent flows, supplemented with a high-pressure equation of state and appropriate redefinitions of the thermodynamic potentials, are introduced in this work based on an extended version of the diffuse-interface theory of van der Waals. The resulting formulation involves revisited forms of the stress tensor and transport fluxes of heat and species, and enables a description of the mesoscopic volumetric effects induced by transcritical interfaces consistently with the thermodynamic phase diagram of the mixture at high pressures. Additionally, applications of the theory are illustrated in canonical problems, including dodecane/nitrogen transcritical interfaces in non-isothermal systems. The results indicate that a transcritical interface is formed between the propellant streams that persists downstream of the injection orifice over distances of the same order as the characteristic thermal-entrance length of the fuel stream. The transcritical interface vanishes at an edge that gives rise to a fully supercritical mixing layer.

02 PETROLEUM↗

DOE OSTI2026

The effect of relative humidity and temperature on the response of stomatal conductance to vapor pressure deficit in tropical trees

Understanding how leaf gas exchange responds to changes in vapor pressure deficit (VPD) is key to predicting tropical forest resilience to climate change. Stomata regulate leaf water and CO2 diffusion, and respond to changes in temperature and relative humidity (RH), two drivers of VPD. At high temperatures, the cuticular pathway may also become significant and participate in the overall leaf conductance. Here, we measured gas exchange under light and dark conditions to investigate the stomatal and cuticular responses to temperature and RH on detached branches in five tropical tree species. Leaf conductance in the dark, when stomata are essentially closed, was not markedly impacted by temperature and RH, suggesting a minimal response of the cuticular pathway to these conditions. We compared six steady-state conductance models incorporating different effects of photosynthesis and evaporative demand on stomatal control. All models performed well (residual standard deviation, σ, < 0.025 mol m-2 s-1), but the best-fitting model (σ = 0.017 mol m-2 s-1) used a nonlinear relationship between photosynthesis and stomatal conductance and incorporated RH rather than vapor pressure difference. All models overestimated the steady-state conductance at high RH. Furthermore, leaf conductance immediately increased after a decrease in RH (wrong-way response), but not after an increase in leaf temperature. This suggests that the mechanisms underlying stomatal response to VPD need further investigation. The non-linear coupling between photosynthetic rate and stomatal conductance indicates a sharper physiological response than previously acknowledged.

Lamour, Julien↗

DOE OSTI2022

Impacts of engine lubrication oil-derived ash on soot oxidative reactivity on a catalytic gasoline particulate filter

Characterizing soot oxidation kinetics is crucial for understanding how gasoline particulate filters (GPFs) perform both in terms of filtration efficiency and pressure drop. The most common method for measuring soot oxidative reactivity is thermogravimetric analysis (TGA). Because TGA is an offline method, it may inaccurately predict how soot oxidizes on a GPF, especially if a catalytic washcoat is present that may enhance oxidation rates through surface interactions as the soot loads on the filter. In this work, a novel in-situ soot oxidative reactivity measurement method was developed. The method involved loading a catalytic GPF under high temperature conditions conducive to soot oxidation and measuring the filtration efficiency of 100 nm particles. A correlation was made between filtration efficiency and loaded soot mass on the filter to allow calculation of the soot oxidation rate. The method was evaluated in experiments using a 2.0 L gasoline direct injection (GDI) engine with three oils of varying additive packages, including an oil with a high zinc dialkyldithiophosphate (ZDDP) concentration, a non-additive, pure poly-alpha olefin (PAO) oil, and an oil with a high concentration of calcium sulfonate. Calculated specific soot oxidation rates ranged from ~0.06–0.6 min –1 and showed strong dependence on GPF inlet gas temperature and lubrication oil additive type. The results clearly demonstrated a catalytic effect of calcium-containing ash particles. Reactivity of soot produced by the engine running with the high calcium containing lubrication oil was increased. Similarly, the results indicated that the catalytic washcoat on the filter increased soot oxidation rates on-filter, especially at low soot loading. Conversely, the ZDDP oil additive exhibited a reactivity inhibiting effect, resulting in lower soot oxidation rates. Finally, this work represents the first known in-situ soot oxidative reactivity measurements on a GPF and elucidates the effect of lubrication oil additives and catalytic washcoat on oxidation rate.

42 ENGINEERING↗

DOE OSTI2023

Low Cost Glass-Ceramic Matrix Composite Heat Exchanger

As part of ARPA-E’s High Intensity Thermal Exchange through Materials and Manufacturing Processes (HITEMMP) program, this project sought to develop novel heat exchanger (HX) capabilities to enable efficient and power dense power generation cycles. This class of HX comes under the category of ceramic/composite materials with the higher temperature goal in the program of ≥1100 °C inlet temperature operation. The enabling capability of this effort is the use of glass-ceramic matrix composite (GCMC) material which provides the high temperature durability of a ceramic, the flaw tolerance of a composite, a significantly faster and lower cost manufacturing process than conventional matrix CMCs and very low porosity levels < 0.5%. For thin-walled HX structures and the need to minimize leakage, the low porosity differentiator is particularly important. RTRC has prior experience with this material system and in the current project advanced the component design and manufacturing methods into new territory to produce features required for effective heat exchange under high pressures. In this approach, silicon carbide fiber is fabricated into a fiber preform using various textile processes. Graphite tooling is used both during the build-up of the fiber preform (interior tooling) and after the fiber preform has been completed (exterior tooling). This tooling assembly is heated to high temperature in an environment that has been evacuated and backfilled with inert gas. A reservoir of specialty glass is present and once the desired temperature has been reached to achieve the desired glass viscosity, an actuator distributes the glass throughout the fiber preform using passageways which are part of the tooling design in a process known as glass transfer molding. After the tooling has been removed, the composite is heat treated to convert the amorphous glass to a crystalline ceramic, providing improved properties. The project was divided into three phases focusing on the following: 1) 10 kW HX design and coupon-level tube sheet fabrication, 2) 10 kW HX fabrication, 3) 50 kW HX fabrication. During Budget Period 1 (BP1), additional risks were encountered and the need for additional funds was agreed upon by ARPA-E program leadership. Due to a variety of factors, the contract modification required nominally 18 months to execute at which time the HITEMMP program was effectively concluding. Because of this and the time that would be required to perform BP2 tasks, it was decided to conclude the project at the end of BP1. During the design of the 10 kW HX, manufacturing constraints were learned and incorporated, leading to a revised configuration for the fiber preform and HX. Heat exchange and pressure drop predictions also played a role in modifying the original design concept to be a higher aspect ratio shell-and-tube HX, simplifying the manufacturing process and improving the heat exchanger performance. Good gravimetric and volumetric thermal power densities of 11.2 kW/kg and 10,200 kW/m3 for the entire HX were projected that involved thermo-structural Finite Element Analysis to determine the structural mass needed for the high operation pressures of 250 bar cold inlet and 80 bar hot inlet. Fiber preforms using textile processes were produced for multiple headered tube sheets. Additional challenges were encountered during the glass transfer molding step for which solutions were identified, but programmatics did not allow them to be implemented in BP1. While complete HX test articles were not fabricated, the benefits of this GCMC material for a variety of high temperature applications remain.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2022

Thermodynamics of the Nonrelativistic Free-Electron Fermi Gas in One, Two, and Three Dimensions from the Degenerate to the Nondegenerate Temperature Regime

The thermodynamic properties of a nonrelativistic free-electron Fermi gas is of fundamental interest in condensed matter physics. Properties previously studied in three-dimensions (3D) in the lowand high-temperature limits include the internal energy, heat capacity, zero-field magnetic spin susceptibility, and pressure. Here we report solutions for the temperature dependence spanning these two temperature regimes of the chemical potential, internal energy, magnetic susceptibility, and the heat capacity at constant volume in 1D, 2D, and 3D. Also calculated are the pressure, enthalpy, heat capacity at constant pressure, isothermal compressibility, and thermal expansion coefficient versus temperature in 2D and 3D. Of primary interest here are the detailed dimension-dependent crossovers of these properties between the degenerate and nondegenerate temperature regime, which are graphically illustrated for each of the above properties.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

High-Fuel Loading Ignition Delay Time Characterization of Hydrogen/Natural Gas/Ammonia at Gas Turbine-Relevant Conditions Inside a High-Pressure Shock Tube

Abstract This study explores the combustion characterization of high-fuel percentage, air-diluted mixtures of H2 mixed with natural gas (NG) as well as mixtures of H2 and NH3 at temperatures and pressures relevant to turbine operating conditions (20–30 bar, 1000–1500 K). Lower temperatures (below 1070 K) exhibit preignition characteristics due to non-homogeneity. An attempt to mitigate these occurrences at high pressures is investigated using the constrained reaction volume (CRV) stage-filling technique. Due to the need to further refine the facility CRV stage-filling uncertainty, only higher temperature data will be interpreted at this time. The test conditions in this study closely replicate the temperatures, pressures, and mixtures that would be seen in hydrogen-powered gas turbines, making it the first to explore such conditions. The experimental IDTs were compared against the current state-of-the-art chemical kinetic models for mechanism validation. The current work will advance H2-powered turbines and aims to determine the optimum molecular ratio of H2 when mixed with natural gas.

Pierro, Michael↗