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All sources NASA NTRS DOE OSTI

DOE OSTI2023

Strategies to overcome mass transfer limitations of hydrogen during anaerobic gaseous fermentations: A comprehensive review

Fermentation of gaseous substrates such as carbon dioxide (CO 2 ) has emerged as a sustainable approach for transforming greenhouse gas emissions into renewable fuels and biochemicals. CO 2 fermentations are catalyzed by hydrogenotrophic methanogens and homoacetogens, these anaerobic microorganisms selectively reduce CO 2 using hydrogen (H 2 ) as electron donor. However, H 2 possesses low solubility in liquid media leading to slow mass transport, limiting the reaction rates of CO 2 reduction. Solving the problems of mass transport of H 2 could boost the advance of technologies for valorizing industrial CO 2 -rich streams, like biogas or syngas. The application could further be extended to combustion flue gases or even atmospheric CO 2 . In this work, an overview of strategies for overcoming H 2 mass transport limitations during methanogenic and acetogenic fermentation of H 2 and CO 2 is presented. Here, the potential for using these strategies in future full-scale facilities and the knowledge gaps for these applications are discussed in detail.

09 BIOMASS FUELS↗

DOE OSTI2024

Utilization of an Advanced Sensor network to determine fuel heating value and Real-Time net unit heat rate during transient operation

Coal-fired utility boilers are being increasingly used as variable electricity generation to resolve the imbalance in the energy market from the expansion of intermittent renewable energy. The frequent transient operation required to meet residual energy demand has created a challenge for coal-fired units to operate efficiently. This work utilizes an advanced sensor network (ASN) to calculate net unit heat rate (NUHR) of a coal-fired boiler in real time through combustion calculations and statistical correlations to provide the tools for optimizing dynamic operation. Real-time heating values that were necessary to determine fuel input energy to calculate accurate NUHR were found using both fundamental and data-driven methods. Real-time NUHR shows distinct shifts that reflect changes in process conditions that will improve the ability to optimize transient operation. Data-driven heating value correlations had 24% lower root mean square error (RMSE) than the fundamental combustion calculation approach when compared to daily retrospective proximate analysis. Furthermore, the data-driven method RMSE improved by 7% with the inclusion of ASN data. Future work is to validate by comparing unit performance with and without the inclusion of NUHR as a control parameter for the dynamic neural network.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Advanced Anode for Internal Reforming and Thermal Management in Solid Oxide Fuel Cells

Solid oxide fuel cell (SOFC) is an efficient and clean electrical power generation system compared to conventional combustion based technologies with energy efficiency reaching as high as 85-90% in co-generation mode (electricity and heat). Other advantages of SOFCs are hybridization, modularity of construction, small CO 2 foot print per kWh of generated electricity and fuel flexibility. Hydrocarbons present in the gaseous fuel is utilized in SOFCs by internal or external reforming. There are two different internal reforming concepts: Direct Internal Reforming (DIR) and Indirect Internal Reforming (IIR). For DIR operation, the endothermic reforming reaction and the exothermic reaction from the oxidation reaction are operated together in the single unit eliminating the requirement for a separate fuel reformer. This configuration also simplifies the overall system design, making SOFC more attractive and efficient means of producing electrical power. The main advantage of the DIR type of operation is that the H 2 or CO consumption by the electrochemical reaction could directly promote the conversion of methane at the anode side of the fuel cell resulting in high conversion and high efficiency. The DIR operation, however, requires an anode material that has desired dual catalytic (hetero and electro) properties for reforming reaction and electrochemical reactions. The anode materials also need to remain resistant to carbon formation at the operating temperature and atmosphere with stable cell performance. Another requirement is to match the reforming reactions and electrochemical reactions to avoid local cooling or overheating, which can result in mechanical failure due to thermally induced stresses. Direct internal reforming (DIR) of hydrocarbon fuels simplifies the overall SOFC system design making it more attractive and efficient for producing electrical power. Low cost alloy anodes for distributed internal reforming of methane and other hydrocarbon fuels offer increased fuel-flexibility, reliability, and long term performance stability of solid oxide fuel cells (SOFC). The research program examined modification of the chemical compositions and microstructure of high entropy alloy (HEA) anode materials using thermochemical calculations and process simulation and modeling to achieve distributed reforming over the entire anode to eliminate hot zones. Cell fabrication and testing of the HEA anodes using button cell configuration has been performed to demonstrate the advantages of new anode over traditional Ni-YSZ anodes for distributed reforming and carbon free operation. Technical accomplishments include identification and synthesis of HEA carbon-resistant anode, demonstration of reduction in reforming rate confirmed by GC and modelling data validating effectiveness for thermal management in cell/stacks, electrochemical testing of HEA anode in single cell (HEA-GDC||YSZ||LSM-YSZ) and Characterization of pretest and posttest anode materials by TEM and SEM-EDS confirming carbon-free operation.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2021

Electrification Futures Study: Scenarios of Power System Evolution and Infrastructure Development for the United States

This report is one in a series of Electrification Futures Study (EFS) publications. The EFS is a multiyear research project to explore potential widespread electrification in the future energy system of the United States. Electrification is defined as the substitution of electricity for direct combustion of non-electricity-based fuels used to provide similar services. The EFS is specifically designed to examine electric technology advancement and adoption for end uses in the major economic sectors of the United States, electricity consumption growth and load profiles, future power system infrastructure development and operations, and economic and environmental implications of electrification. Because of the expansive scope and the multiyear duration of the study, research findings and supporting data will be published as a series of reports, with each report being released on its own time frame.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

NASA NTRS1979

The Advanced Low-Emissions Catalytic-Combustor Program: Phase I - Description and status

The Advanced Low-Emissions Catalytic-Combustor Program is an ongoing three-phase contract effort with the primary objective of evolving the technology required for incorporating catalytic combustors into advanced aircraft gas-turbine engines. Phase I is currently in progress. At the present time, analytical evaluation is being conducted on advanced catalytic-combustor concepts, including variable geometry, with their known inherent potential advantages of low-level pollutant emissions, widened combustion stability limits, and reduced pattern factor for longer turbine life. Phases II and III will consist of experimental evaluation of the most promising concepts.

Szaniszlo, A. J.↗

NASA NTRS1981

An overview of general aviation propulsion research programs at NASA Lewis Research Center

The review covers near-term improvements for current-type piston engines, as well as studies and limited corroborative research on several advanced g/a engine concepts, including diesels, small turboprops and both piston and rotary stratified-charge engines. Also described is basic combustion research, cycle modeling and diagnostic instrumentation work that is required to make new engines a reality.

Willis, E. A.↗

NASA NTRS1981

An overview of general aviation propulsion research programs at NASA-Lewis Research Center

This paper presents a brief overview and technical highlights of general aviation (g/a) propulsion research efforts and studies which have been underway at NASA's Lewis Research Center (LeRC) for the past several years. The review covers near-term improvements for current-type piston engines, as well as studies and limited corroborative research on several advanced g/a engine concepts, including diesels, small turboprops and both piston and rotary stratified-charge engines. Also described is basic combustion research, cycle modeling and diagnostic instrumentation work that will be required to make the new engines a reality. The discussion emphasizes the most recently-completed studies and the basic underlying research work, which have not been reported previously.

Willis, E. A.↗

NASA NTRS1983

An overview of general aviation propulsion research programs at NASA Lewis Research Center

Willis, E. A.↗

NASA NTRS1983

Application of 3D aerodynamic/combustion model to combustor primary zone study

A description is provided of the three-dimensional elliptic code for reacting flows used in the combustor design process during the program 'Small Gas Turbine Combustor Primary Zone Study' carried out by a U.S. company. The code, designated MARC-I (multidimensional aerodynamic recirculating combustion-Version I) is an adaptation of the model described by Mongia et al. (1979). The program has the objective to advance the technology of the small reverse-flow annular combustor design through an understanding of primary zone performance factors. The MARC-I code was used for performance predictions of both original designs and later modifications. A test program consisting of both primary zone sampling and overall combustor performance measurements was carried out. It was, therefore, possible to compare the analytical predictions with actual test measurements.

Sullivan, R. E.↗

NASA NTRS1989

Liquid Behavior at Critical and Supercritical Conditions

At a JANNAF workshop, the issue of fluids at and above the critical point was discussed to obtain a better understanding of similar conditions in combustion chambers of rocket engines. Invited experts from academic, industrial, and government institutions presented the most recent physical, numerical, and experimental advances. During the final discussion period, it was agreed that: (1) no analytical capability exists to simulate subject conditions; (2) mechanisms reflected by opalescence, the solubility of gases, other interfacial phenomena listed, and fluorescence diagnostics are new and important; (3) multicomponent mixtures, radiation, critical fluctuation, and other recorded ones pose unknown effects; and (4) various identified analytical and experimental actions must be initiated in a mutually supporting sequence.

Chiu, Huei-Huang↗

NASA NTRS1992

OSSA Space Station Freedom science utilization plans

Long duration exposure to an essentially zero-gravity environment is a phenomenon exclusive to the Space Station Freedom that cannot be duplicated on Earth. The Freedom Station will offer periods of time on orbit extending to weeks and months rather than hours or days, allowing for in-depth space based research and analysis to a degree never before achieved. OSSA remains committed to exploiting the unique capabilities provided by the Space Station as well as other space-based facilities to study the nature of physical, chemical, and biological processes in a low-gravity environment and to apply these studies to advance science and applications in such fields as biomedical research, plant and animal physiology, exobiology, biotechnology, materials science, fluid physics, and combustion science. The OSSA focus is on progressive science investigations, many requiring hands-on scientist involvement using sophisticated experiment hardware. OSSA science utilization planning for the Freedom Station is firmly established. For this presentation, this planning is discussed in three general areas: OSSA goals and overall approach, the current and on-going program, and plans for space station utilization. In the first area, OSSA addresses its overall approach to space science research, its commitment to transition to Space Station Freedom, and its top-level strategy for the utilization of Freedom. The current and on-going program is next discussed, focusing on the various Spacelab series of missions which are providing the stepping-stones to Space Station Freedom. Selected science results from SLS-1 and USML-1 are cited which underline the value of properly outfitted laboratories in space in which crew-intensive experiment interactions are possible. The presentation is concluded with a discussion of top-level goals and strategies for utilizing the Freedom Station by OSSA's Life Sciences Division and its Microgravity Science and Applications Division.

Cressy, Philip J.↗

NASA NTRS1993

Spray Combustion Experiments and Numerical Predictions

The next generation of commercial aircraft will include turbofan engines with performances significantly better than those in the current fleet. Control of particulate and gaseous emissions will also be an integral part of the engine design criteria. These performance and emission requirements present a technical challenge for the combustor: control of the fuel and air mixing and control of the local stoichiometry will have to be maintained much more rigorously than combustors in current production. A better understanding of the flow physics of liquid fuel spray combustion is necessary. This presentation describes recent experiments on spray combustion where detailed measurements of the spray characteristics were made, including local drop-size distributions and velocities. In addition, an advanced combustor CFD code has been under development and predictions from this code are presented and compared with measurements. Studies such as these will provide information to the advanced combustor designer on fuel spray quality and mixing effectiveness. Validation of new fast, robust, and efficient CFD codes will also enable the combustor designer to use them as valuable design tools for optimization of combustor concepts for the next generation of aircraft engines.

Mularz, Edward J.↗

NASA NTRS2016

Processing and Characterization of Thousand-Hour 500 C Durable 4H-SiC JFET Integrated Circuits

This work reports fabrication and testing of integrated circuits (ICs) with two levels of interconnect that consistently achieve greater than 1000 hours of stable electrical operation at 500 C in air ambient. These ICs are based on 4H-SiC junction field effect transistor (JFET) technology that integrates hafnium ohmic contacts with TaSi2 interconnects and SiO2 and Si3N4 dielectric layers over approximately 1-micrometer scale vertical topology. Following initial burn-in, important circuit parameters remain stable for more than 1000 hours of 500 C operational testing. These results advance the technology foundation for realizing long-term durable 500 C ICs with increased functional capability for sensing and control combustion engine, planetary, deep-well drilling, and other harsh-environment applications.

Microelectronics↗

NASA NTRS2016

Processing and Characterization of Thousand-Hour 500 C Durable 4H-SiC JFET Integrated Circuits

This work reports fabrication and testing of integrated circuits (ICs) with two levels of interconnect that consistently achieve greater than 1000 hours of stable electrical operation at 500 C in air ambient. These ICs are based on 4H-SiC junction field effect transistor (JFET) technology that integrates hafnium ohmic contacts with TaSi2 interconnects and SiO2 and Si3N4 dielectric layers over 1-m scale vertical topology. Following initial burn-in, important circuit parameters remain stable for more than 1000 hours of 500 C operational testing. These results advance the technology foundation for realizing long-term durable 500 C ICs with increased functional capability for sensing and control combustion engine, planetary, deep-well drilling, and other harsh-environment applications.

JFET↗

DOE OSTI2021

Supercritical Carbon Dioxide Primary Power Large-Scale Pilot Plant

The United States electrical power generation fleet encompasses a wide range of technologies, ranging from traditional combustion-based power generation, to nuclear power, to renewable energy. While the distribution of these assets continues to shift due to economic and regulatory influences, coal combustion continues to be a key part of the US energy portfolio. Despite the relative maturity of coal combustion technology, improvements in overall fuel-to-power efficiency and generation flexibility are still possible and will improve both the economic and environmental factors of coal combustion. Echogen Power Systems proposes to lead a world-class team including the University of Missouri, Electric Power Research Institute and Louis Perry Associates in the design, construction and operation of a 10MWe coal-fired supercritical carbon dioxide (sCO 2 ) large-scale pilot. This transformational technology uses sCO 2 as a working fluid instead of water to achieve high thermodynamic efficiencies that can significantly exceed advanced steam-Rankine cycles. Further, the compact nature of sCO 2 turbomachinery offers capital cost and footprint advantages, and the low maintenance of a water-free power cycle can significantly reduce operation and maintenance (O&M) costs over conventional steam-Rankine systems. Recent integration studies of sCO 2 with coal combustion power plants highlight the significant improvements in plant efficiency that sCO 2 can offer relative to even advanced steam Rankine cycles. At commercial scales, coal-sCO 2 plant net efficiency is predicted to be 39-44.0% (HHV), or 10-20% higher output than conventional steam-Rankine systems, which will significantly improve the competitiveness of coal-fired generation. This proposal builds upon projects previously funded by the Department of Energy, including DE-FE0025959 (High-Efficiency Thermal Integration of Closed Supercritical CO 2 Brayton Power Cycles with Oxy-Fired Heaters) and DE-NE0008470 (Conceptual Design for sCO 2 Power Cycle Test Facility). An appropriately-scaled and properly designed and operated pilot project is essential to overcome the natural risk-aversion of the power generation industry and project financing community. The 10 MWe coal-fired sCO 2 pilot power plant proposed herein will reduce the technical and economic risk of this transformational technology, enabling commercial deployment at the conclusion of the project. For the second phase of this project, Echogen lead a team that completed and refined the pilot system conceptual system and key component designs resulting in the completion of a front-end-engineering-design (FEED) study, completed the NEPA review process, completed the permitting process for construction and operation, refined the techno-economic analysis of the proposed system at commercial scale and received commitments for Phase III cost share. The end result of the program will be to demonstrate the technical and economic superiority of the sCO 2 power cycle for coal-fired operation. Major risk elements will have been retired with sufficient operation at high power to enable the power generation industry to move forward with the first commercial deployment of this transformational system.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2022

An indirect approach to optimize the reaction rates of thermal NO formation for diesel engines

With stringent emission regulations, it has become more important for modern diesel engine manufacturers to accurately predict engine-out nitrogen oxide (NO x ) emissions across a wide range of operating conditions. Thermal NO is the major source of engine-out NO x in modern diesel engines. For thermal NO formation, several earlier studies have recommended the forward and reverse reaction rate coefficients of the rate-limiting reaction (O + N 2 ⇌ NO + N). However, due to deficiencies in sub-models and inadequacies of reduced chemical mechanisms to represent diesel combustion, these recommended values more often than not need to be adjusted in reduced order combustion models to accurately predict engine-out NO x . Hence, in this work a systematic and computationally efficient approach has been proposed to streamline the process of determining the optimum reaction rate coefficients. Here, to develop the optimization approach, four different production diesel engines with different operating conditions in terms of speed, load, and exhaust-gas recirculation have been considered. Numerical simulations have been performed using a detailed zero-dimensional velocity-composition-frequency transported probability density function (0D-VCF-tPDF) model that uses hundreds of notional particles to capture in-cylinder stratification. Four different combinations of hydrocarbon and NO x chemical mechanisms were used to represent chemistry. It was found that for the rate-limiting reaction, the pre-exponent factors (A f1 , A r1 ) and activation energies (E A,f1 , E A,r1 ) of the forward and reverse reaction rates follow a linear band in A f1 - E A,f1 and A r1 - E A,r1 space where predicted engine-out NO x match the measured values closely. By encompassing such bands from different engines and considering constraints on activation energies, a reduced search domain of pre-exponent factors and activation energies was constructed that is expected to be applicable to any diesel engine. Eventually, computationally efficient three-line and one-line search approaches were proposed to determine the optimum values of the pre-exponent factors and activation energies that led to a minimum error between measured and predicted engine-out NO x . Finally, these three-line and one-line NO x optimization approaches were applied to a fifth production diesel engine for which the 0D-VCF-tPDF model showed a very good predictive performance in terms of predicting peak pressure, 50% burn rate, and engine-out NO x when compared to measured and 3D-CFD values.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2024

Understanding the interplay between pilot fuel mixing and auto-ignition chemistry in hydrogen-enriched environment

The diesel-piloted dual-fuel compression ignition combustion strategy is well-suited to accelerate the decarbonization of transportation by adopting hydrogen as a renewable energy carrier into the existing internal combustion engine with minimal engine modifications. Despite the simplicity of engine modification, many questions remain unanswered regarding the optimal pilot injection strategy for reliable ignition with minimum pilot fuel consumption. The present study uses a single-cylinder heavy-duty optical engine to explore the phenomenology and underlying mechanisms governing the pilot fuel ignition and the subsequent combustion of a premixed hydrogen-air charge. The engine is operated in a dual-fuel mode with hydrogen premixed into the engine intake charge with a direct pilot injection of n-heptane as a diesel pilot fuel surrogate. Optical diagnostics used to visualize in-cylinder combustion phenomena include high-speed IR imaging of the pilot fuel spray evolution as well as high-speed HCHO* and OH* chemiluminescence as indicators of low-temperature and high-temperature heat release, respectively. Three pilot injection strategies are compared to explore the effects of pilot fuel mass, injection pressure, and injection duration on the probability and repeatability of successful ignition. The thermodynamic and imaging data analysis supported by zero-dimensional chemical kinetics simulations revealed a complex interplay between the physical and chemical processes governing the pilot fuel ignition process in a hydrogen containing charge. Hydrogen strongly inhibits the ignition of pilot fuel mixtures and therefore requires longer injection duration to create zones with sufficiently high pilot fuel concentration for successful ignition. Results show that ignition typically tends to rely on stochastic pockets with high pilot fuel concentration, which results in poor repeatability of combustion and frequent misfiring. In conclusion, this work has improved the understanding on how the unique chemical properties of hydrogen pose a challenge for maximization of hydrogen’s energy share in hydrogen dual-fuel engines and highlights a potential mitigation pathway.

33 ADVANCED PROPULSION SYSTEMS↗

NASA NTRS2002

Oxidation Behavior of GRCop-84 Copper Alloy Assessed

NASA's goal of safe, affordable space transportation calls for increased reliability and lifetimes of launch vehicles, and significant reductions of launch costs. The areas targeted for enhanced performance in the next generation of reusable launch vehicles include combustion chambers and nozzle ramps; therefore, the search is on for suitable liner materials for these components. GRCop-84 (Cu-8Cr-4Nb), an advanced copper alloy developed at the NASA Glenn Research Center in conjunction with Case Western Reserve University, is a candidate. The current liner of the Space Shuttle Main Engine is another copper alloy, NARloy-Z (Cu-3Ag-0.1Zr). It provides a benchmark against which to compare the properties of candidate successors. The thermomechanical properties of GRCop-84 have been shown to be superior, and its physical properties comparable, to those of NARloy-Z. However, environmental durability issues control longevity in this application: because copper oxide scales are not highly protective, most copper alloys are quickly consumed in oxygen environments at elevated temperatures. In consequence, NARloy-Z and most other copper alloys are prone to blanching, a degradation process that occurs through cycles of oxidation-reduction as the oxide is repeatedly formed and removed because of microscale fluctuations in the oxygen-hydrogen fuel systems of rocket engines. The Space Shuttle Main Engine lining typically degraded by blanching-induced hot spots that lead to surface roughening, pore formation, and coolant leakage. Therefore, resistance to oxidation and blanching are key requirements for second-generation reusable launch vehicle liners. The rocket engine ambient includes H2 (fuel) and H2O (combustion product) and is, hence, under reduced oxygen partial pressures. Accordingly, our studies were expanded to include oxygen partial pressures as low as 322 parts per million (ppm) at the temperatures likely to be experienced in service. A comparison of 10-hr weight gains of GRCop-84, NARloy-Z, and pure copper in 0.032, 2.2, and 100 percent oxygen from 550 to 750 C is shown. In 2.2 vol% and higher oxygen content, GRCop-84 oxidation was slower than that of NARloy-Z or Cu, but that advantage was lost or diminished in 322-ppm O2. Over longer (50-hr) exposures in 1.0 atm O2, however, the advantage of GRCop-84 increased significantly, its oxidation rate becoming approximately 10 times slower than those of Cu and NARloy-Z from 500 to 700 C. Weight gains were moderate and the kinetics parabolic for all three materials in 2.2 vol% and higher oxygen content; however, in 322-ppm O2, the scales were nonprotective below about 650 C, as reflected in linear kinetics and large weight gains. The superior oxidation resistance of GRCop-84 is likely related to the kinetics of extra oxygen consumption to form the additional oxides of Cr and Nb detected beneath the GRCop-84 oxide layer. While we continue to evaluate the blanching resistance of GRCop-84 in other tests, these oxidation results indicate that GRCop-84 is suitable as a reusable launch vehicle liner, and in applications where it is desired to use a copper alloy but without the risk of oxidative failure. Three bar charts comparing overall specific weight gains by each of the three materials studied. The top chart is for oxidation in 1.0 atm of oxygen, the middle is for 2.2% oxygen (balance argon), and the bottom is for 0.0322% oxygen. GRCop-84 outperforms the other two materials, showing the least weight gain in nearly all cases.

Thomas-Ogbuji, Linus U.↗