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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 847 records · Page 47
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

System Design of a 2.0 MWth Sodium/Molten Salt Pilot System

Nitrate molten salt concentrating solar power (CSP) systems are currently deployed globally and are considered state-of the art heat transfer fluids (HTFs) for present day high-temperature operation. Although slightly higher limits may be possible with molten salt, to fully realize SunShot efficiency goals of $15/kWhth HTFs and an LCOE of 6¢/kWh, HTF technologies working at higher temperatures (e.g., 650 °C to 750 °C) will require an alternative to molten salts, such as with alkali metal systems. This investigation explores the development of a 2.0 MWth sodium receiver system that employs a sodium receiver as the HTF, as well as with a ternary chloride (20%NaCl/40%MgCl/40%KCl by mol wt.%) salt as a thermal energy storage (TES) medium to facilitate a 6-hr. storage duration. A sodium-to-salt heat exchanger model as well as a salt-to-sCO2 primary heat exchanger model are employed and evaluated in this investigation. A thermodynamic system design model was developed using Engineering Equation Solver (EES) where state properties were calculated at inlets and outlets along both hot and cold legs of the pilot-scale plant. This investigation assesses receiver performance as well as system efficiency studies for the pump and system operational ranges. Results found that high efficiency sodium receivers were found to have higher heat transfer coefficients and required far less spreading of incident flux. The system performance model results suggest that for a pump speed of 2400 RPM, respective hot and cold pump TDH values were determined to be 260.1–307 ft. and 260.1–307 ft for pump flow rates of 90–120 GPM.

41 EE - Solar Energy Technologies Office (EE-4S)↗
DOE OSTI2023

Multiphase Modeling in a Parallel Plate Fluidized Bed Receiver for Concentrating Solar Power

A novel high temperature particle solar receiver is developed by using a light trapping planar cavity configuration. As particles fall through the cavity, the concentrated solar radiation warms the boundaries of the receiver and in turn heats the particles. Particles flow through the system, forming a packed bed at the lower end, leaving the system from the bottom at a constant flow rate. Air is introduced to the system as the fluidizing medium to improve particle heat transfer and mixing. A laboratory scale cavity receiver is built and a near IR quartz lamp is used to provide flux to the vertical wall of the heat exchanger. The system is modeled using a continuum two-fluid method. The computational model matches the experimental system size and the particle size distribution is assumed monodisperse. A conduction model that accounts for the effects of solid concentration is implemented, and the heat flux boundary condition matches the experimental setup. Radiative heat transfer is estimated using a widely used correlation during the post-processing step to determine an overall heat transfer coefficient. The model is validated against testing data and achieves less than 30% discrepancy and a heat transfer coefficient greater than 1000 W/m2K.

CSP↗
DOE OSTI2021

Can Bump Arrays Separate Particles from Turbulent Flows?

In this paper, we evaluate the hypothesis that bump arrays can be used to separate particles from turbulent flows entering the array. Microfluidic bump arrays are known for separating particles by size from laminar inlet flows. However, turbulent inlet flows have not been explored but become important as microfluidic bump arrays are scaled up to mesofluidic bump arrays. We find experimentally that particle separation is indeed effective at higher Reynolds numbers. These experimental findings portend industrial scale particle separation due to the higher flow rates they facilitate.

Pease, Leonard F.↗
DOE OSTI2021

Incorporating Valve Switching Losses Into a Static Optimal Control Algorithm for the Hybrid Hydraulic-Electric Architecture (HHEA)

The Hybrid Hydraulic-Electric Architecture (HHEA) has, in recent years, been proposed as an energy efficient alternative to conventional load-sensing architectures in mobile machines such as excavators and wheel-loaders. HHEA leverages the advantages of hydraulic power and electric power to eliminate throttling valves while also improving the energy and control performance of the system. The architecture utilizes a set of common pressure rails to provide a majority of power and and a small electric motor driven pump to modulate this power to meet the exact demand. Previous work has developed a computationally efficient Lagrange Multiplier approach for determining the optimal pressure rail selections that minimizes the energy losses in the system. The static model used considers only the energy use for each pressure rail selection but not the losses associated with the valves during the transition. This paper presents an approach to include the switching losses in the model and in the optimization procedure. To capture the switching losses, switching events between different rails and at various input and output flow rates were simulated with consideration of valve spool dynamics. A parameterized model that summarizes the losses is then obtained, allowing switching losses to be added to the previous energy analysis. The performance of the switching loss model was compared with reference data obtained from a high-fidelity simulation model. To incorporate the switching losses into optimal control algorithm, an efficient dynamic programming approach that prevents frequent switching is adopted in place of the Lagrange multiplier approach. The overall effect of switching losses on the energy consumption and optimal control decisions is presented. In general, switching losses contribute to about 9–10% of input energy.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2022

Accumulator Sizing for the Hybrid Hydraulic Electric Architecture (HHEA) Using Dynamic Programming

Abstract The Hybrid Hydraulic Electric Architecture (HHEA) is an approach to electrifying and improving that does not require very large electric machines. The majority power is provided hydraulically via a set of common pressure rails while small electric machines are used to modulate that power to meet exact demand. Each common pressure rail has an accumulator, which keeps the pressure of each rail near constant as long as the volume in the accumulator does not change much. A main pump adds or removes fluid from each accumulator as needed to reduce volume changes in the accumulators. It is the operation of this main pump which is investigated here. In previous analysis it was assumed that the size of the accumulators was large enough to account for any difference in fluid volume without significantly changing the pressure. In this paper, the required accumulator sizes are studied using a dynamic programming approach. At each time step the inlet and outlet of the main pump could be connected to any of the common pressure rails. These decisions for the main pump were optimized to minimize the required accumulator size. Case studies are conducted using drive cycles from a 22-ton excavator, a 20-ton wheel loader and a 5-ton excavator. The machines could be operated with total accumulator sizes of less than 20, 10, and 5 liters respectively. Required accumulator size was found to vary with pump flow rate, the frequency at which the pump/motor was able to change operating conditions, the tolerance level of pressure deviation and the accumulator’s polytropic index.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2023

Design and Cooling Performance of Additively Manufactured Ceramic Turbine Vanes

Ceramic materials are of significant interest in aviation and power generation gas turbine engines due to their low density and ability to withstand high temperatures. Increased cycle thermal efficiency and higher specific power output is possible by incorporating ceramic components that enable high turbine inlet temperatures and lower required cooling airflow levels. However, ceramics can be difficult and costly to form into the complex shapes used in gas turbine components, often requiring specialized multi-step processes. Furthermore, ceramic components in the hottest areas of a gas turbine, such as vanes or blade shroud seals, will still likely require cooling which is challenging to implement in conventional ceramic manufacturing approaches. Therefore, this study presents a multidisciplinary approach that investigates the design, fabrication and overall cooling effectiveness evaluation of additively manufactured (AM), polymer derived ceramic (PDC) turbine vanes. A thermo-mechanically optimized vane design was generated, ceramic additive manufacturing of the complex cooling configuration was developed, and quantification of the increase in overall cooling effectiveness was performed in a 1X scale, high-speed facility using infrared thermography. This study produced a PDC AM process, capable of printing complex internal cooling schemes in 1X scale turbine vanes. It was found that the optimized vane more than doubled the overall cooling effectiveness observed in the baseline design, which reasonably agreed with thermomechanical optimization model predictions. Additionally, the optimized ceramic vane outperformed an identical metal vane, in terms of area averaged cooling effectiveness, suggesting that the ceramic vane could operate at reduced coolant flow rates to achieve comparable levels of cooling performance.

Fox, Andrew↗
DOE OSTI2023

THE IMPACT OF OXIDATION-INDUCED DEGRADATION ON MATERIALS USED IN HYDROGEN-FIRED MICROTURBINES

Hydrogen-fueled microturbines are being considered as part of the future green microgrid. However, the use of hydrogen as a fuel presents new challenges for selection and development of suitable high temperature materials for hydrogen combustion. The burning of hydrogen is expected to result in higher operating temperatures and higher than typically observed water vapor contents in exhaust gases than after burning natural gas. In the present work, foil specimens of various Fe- and Ni-based alloys were oxidized in air + 10vol.% H2O and air + 60vol.% H2O for up to 5,000 h at 700 °C to simulate the exhaust atmosphere of natural gas and hydrogen-fueled microturbines. The impact of alloy composition and water vapor content on the oxidation/ volatilization induced loss of wall thickness was experimentally evaluated. Enhanced external oxidation and volatilization of Cr¬2O3 and Ti-doped Cr2O3 scales was observed in 60 % H2O compared to 10% H2O. No significant impact of the higher water vapor content was observed on Al2O3 scales formed on Fe-based alumina forming alloys. Lifetime modeling was employed to predict the combined effects of water vapor content, gas flow rates, temperature and alloy composition on the oxidation-induced lifetime of the investigated materials

Romedenne, Marie↗
DOE OSTI2022

EXPERIMENTAL AND MODELLING ANALYSIS OF A LARGE-SCALE TWO-PHASE LOOP THERMOSYPHON

Liquid pumping requires large quantities of electrical energy, including about 7% of the energy of building heating, ventilation, and air conditioning (HVAC) systems. To replace pumped condenser-cooling tower water loops with a passive alternative system, we implemented a commercial-scale two-phase loop thermosyphon (TPLT). The unit consists of a 13 m riser integrated with a commercially available cooling tower and circulation water heater that simulates heat loads up to 25 kW. In addition to providing passive cooling capabilities, the cooling tower unit is also maintenance free, reliable, and can operate in both dry and wet modes. This study characterizes the performance (temperature difference between the evaporator and condenser) and the two-phase flow behavior of the loop under various refrigerant charges. Sight glasses installed throughout the loop are used to identify the operating flow regimes in the riser and downcomer. Over the range of operating conditions, we identified that there is an optimal refrigerant charge range for a specific heat load at which near-isothermal operation can be achieved. We further developed a model to predict the operating flow rate and gravitational height in the downcomer and compared it with the experimental data. The results show that the model agrees with the experimental data, in particular the threshold gravitational head height at which there will be subcooled liquid at the condenser exit, indicating that it can be used as a predictive tool for identifying the optimal loop charge for a given heat load.

Loop thermosyphon, passive two phase↗
DOE OSTI2022

Thermal Optimization of a Silicon Carbide, Half-Bridge Power Module

This project describes the modeling process to design the packaging and heat exchanger for a half-bridge wide-bandgap (WBG) power semiconductor module. The module uses two silicon carbide, metal-oxide-semiconductor field-effect transistor (MOSFET) devices per switch position that are soldered to an aluminum nitride, direct-bond copper (DBC) substrate. A baseplate cooling configuration (e.g., no thermal grease) is used along with a water-ethylene glycol, jet-impingement-style heat exchanger. The heat exchanger was designed to be fabricated using prototyping equipment from the National Renewable Energy Laboratory, complies with automotive standards (for minimal channel sizes, flow rates, and coolant), and considers reliability aspects (i.e., erosion/corrosion). Device-scale computational fluid dynamics (CFD) is used first to design the slot jet impingement cooling configuration and compute the effective heat transfer coefficient (HTC) of the concept. The computed HTCs are then used as boundary conditions for a finite element study to optimize the package geometry (e.g., device layout and baseplate thickness) to minimize thermal resistance and minimize temperature variation between the module's four devices. Finally, a fluid manifold is designed to generate the slot jets and cool the devices. Module-scale CFD predicts a relatively low junction-to-fluid thermal resistance of 16.7 mm2 K/W, a 1.4 degrees C temperature variation between devices, and a total pressure drop of 5,860 Pa (0.85 psi) for the design. The thermal resistance of the module design is about 67% lower than the 2015 BMW i3 power electronics/modules thermal resistance.

DIRECT ENERGY CONVERSION↗
DOE OSTI2020

Highly selective Si 3 N 4 /SiO 2 etching using an NF 3 /N 2 /O 2 /H 2 remote plasma. I. Plasma source and critical fluxes

Highly selective plasma etching of silicon nitride (Si 3 N 4 ), while not etching silicon dioxide (SiO 2 ), is a critical step in the fabrication of microelectronics devices. In many applications, this etching must be damage-free and isotropic, which then motivates the use of remote plasmas where the reactants interacting with the substrate are dominantly neutral species. In this paper and Paper II, mechanisms for highly selective Si 3 N 4 etching in remote plasmas are discussed based on results from experiments and simulations. It has been shown experimentally that high Si 3 N 4 /SiO 2 etch selectivity (≈380) can be achieved in the downstream effluent of an NF 3 /N 2 /O 2 /H 2 plasma. The authors found that H2 plays a principal role in the reaction mechanism as Si 3 N 4 /SiO 2 selectivity shows a sharp maximum as a function of the H2 flow rate. Based on this observation, and measured densities of F-atoms and H2 in the process chamber, a mechanism of selective Si 3 N 4 /SiO 2 etching is proposed in which HF molecules in vibrationally excited states accelerate etching reactions. A reaction mechanism for NF 3 /N 2 /O 2 /H 2 plasmas and its afterglow was developed to computationally determine the species densities and fluxes on the wafer level, validated by comparing with experimentally measured F-atom and H 2 densities. The calculated species densities and fluxes were used as input to an analytical model of Si 3 N 4 and SiO 2 etching based on the results of quantum chemistry simulations. This paper presents experimental results (etching data and species densities), the reaction mechanism for NF 3 /N 2 /O 2 /H 2 plasmas, and the results of simulations of gas phase chemistry. Quantum chemistry simulations of elementary etching reactions, description of the analytical model of Si 3 N 4 and SiO 2 etching, calculations of the etch rates, and Si 3 N 4 and SiO 2 selectivity with this model are presented in Paper II.

42 ENGINEERING↗
DOE OSTI2020

Highly selective Si 3 N 4 /SiO 2 etching using an NF 3 /N 2 /O 2 /H 2 remote plasma. II. Surface reaction mechanism

Developing processes for highly selective etching of silicon nitride (Si 3 N 4 ) with respect to silicon dioxide (SiO 2 ) is a major priority for semiconductor fabrication processing. In this paper and in Paper I [Volynets et al., J. Vac. Sci. Technol. A 38, 023007 (2020)], mechanisms are discussed for highly selective Si3N4 etching in a remote plasma based on experimental and theoretical investigations. The Si 3 N 4 /SiO 2 etch selectivity of up to 380 was experimentally produced using a remote plasma sustained in NF 3 /N 2 /O 2 /H 2 mixtures. A selectivity strongly depends on the flow rate of H 2 , an effect attributed to the formation of HF molecules in vibrationally excited states that accelerate etching reactions. Based on experimental measurements and zero-dimensional plasma simulations, an analytical etching model was developed for etch rates as a function of process parameters. Reaction rates and sticking coefficients were provided by quantum chemistry models and also fitted to the experimental results. Etch rates from the analytical model show good agreement with the experimental results and demonstrate why certain etchants accelerate or inhibit the etch process. In particular, the modeling shows the important role of HF molecules in the first vibrationally excited state [HF( v = 1)] in achieving high Si 3 N 4 /SiO 2 selectivity.

42 ENGINEERING↗
DOE OSTI2020

In-Cu alloy substrates for low-temperature chemical vapor deposition of Mo2C

Two-dimensional transition metal carbides are promising materials because of their potential for combining the favorable properties of transition metal carbides with the high aspect ratio of two-dimensional materials. Though commonly produced by top-down wet-chemical synthesis methods, synthesis by chemical vapor deposition is being considered because of its ability to achieve large areas, controlled layer thickness, and reduced defect density. Typically, liquid Cu is used as a synthesis substrate, though the high melting temperature of Cu (1085 °C) requires high synthesis temperatures. Thus, alternative substrates have been studied in order to reduce the necessary melting temperature. This work systematically studies the impact of synthesis parameters and substrate composition on the growth of ultrathin Mo2C (∼4–120 nm thick) by chemical vapor deposition on an In-Cu alloy. Mo2C flake size increases, and graphene/Mo2C heterostructures form with an increase in the methane flow rates. Increasing the In composition slightly decreases surface coverage and coalescence but does not appreciably impact the Mo2C flake size. Increasing In content also decreases the alloy substrate melting temperature so that a lower temperature synthesis (800 °C) can be performed. However, the necessary high temperatures for pyrolysis of methane lead to a lower limit for the synthesis temperature, similar to graphene.

Young, Katherine T. (ORCID:0000000285845576)↗
DOE OSTI2025

Magnetized, radiofrequency-driven hollow cathode chemical-vapor deposition of ultrathick hydrogenated amorphous carbon

Amorphous carbon is an attractive material for next-generation inertial confinement fusion (ICF) ablators due to its amorphous structure, tunable density, compatibility with dopants, chemical inertness, and mechanical robustness. Ablators are typically deposited as ultrathick (10–200 μm) coatings on removable spherical templates. The deposition of such thick amorphous carbon films is challenging due to high intrinsic compressive stress, which causes film buckling and delamination. Here, we study the deposition of amorphous carbon films by magnetized, radiofrequency-driven hollow cathode chemical vapor deposition with a custom-designed source in Ne plasmas. Emphasis is on the hollow-cathode source design and effects of the plasma discharge power and the precursor flow rate on film properties. We demonstrate deposition rates of >1 μm/h for films with hydrogen content of ∼40 at. %, densities of 1.1–1.7 g/cm 3 , and trace quantities of oxygen impurities. In conclusion, we also demonstrate the feasibility of depositing thick hydrogenated amorphous carbon films (∼30 μm) for ICF applications.

Carbon based materials↗
DOE OSTI2023

Digital holography for real-time non-invasive monitoring of larval fish at power plant intakes

Effective evaluation of technological and operational approaches to reduce entrainment of marine organisms at cooling water intake structures (CWIS) requires accurate organism-sensing systems. Current detection methods lead to large temporal data gaps, require tedious manual analysis, and are fatal to organisms. In this report we describe integrating deep learning with a non-lethal, non-intrusive imaging method—digital holography—to rapidly detect fish larvae. Laboratory experiments demonstrated that the instrument could successfully image fish larvae at flow rates exceeding ranges seen in CWIS. Holograms of two fish larvae species, in the presence of bubbles and detritus, were collected to build a large database for training a lightweight convolutional neural network. The model achieves 97% extraction accuracy in quantifying larvae, and distinguishing them from other particles, including detritus and bubbles, when applied to a dataset of manually classified images, exceeding previous metrics for non-lethal, accurate, and real-time detection. These results demonstrate the potential of in situ holographic imaging for monitoring endangered larval fish species at power plant intake structures, and for high-fidelity, real-time applications in monitoring aquatic ichthyoplankton.

endangered species↗
DOE OSTI2022

Nonidealities in Rotating Detonation Engines

A rotating detonation engine (RDE) is a realization of pressure-gain combustion, wherein a traveling detonation wave confined in a chamber provides shock-based compression along with chemical heat release. Due to the high wave speeds, such devices can process high mass flow rates in small volumes, leading to compact and unconventional designs. RDEs involve unsteady and multiscale physics, and their operational characteristics are determined by an equilibrium between large- and small-scale processes. While RDEs can provide a significant theoretical gain in efficiency, achieving this improvement requires an understanding of the multiscale coupling. Specifically, unavoidable nonidealities, such as unsteady mixing, secondary combustion, and multiple competing waves associated with practical designs, need to be understood and managed. The secondary combustion processes arise from fuel/air injection and unsteady and incomplete mixing, and can create spurious losses. In addition, a combination of multiple detonation and secondary waves compete and define the dynamical behavior of mixing, heat release distribution, and the overall mode of operation of the device. This review discusses the current understanding of such nonidealities and describes the tools and techniques used to gain insight into the extreme unsteady environment in such combustors.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

Editors’ Choice—Flooded by Success: On the Role of Electrode Wettability in CO 2 Electrolyzers that Generate Liquid Products

Economic operation of carbon dioxide (CO 2 ) electrolyzers generating liquid products will likely require high reactant conversions and product concentrations, conditions anticipated to challenge existing gas diffusion electrodes (GDEs). Notably, electrode wettability will increase as lower surface tension products (e.g., formic acid, alcohols) are introduced into electrolyte streams, potentially leading to flooding. To understand the hydraulically stable operating envelopes in mixed aqueous-organic liquid domains, we connect intrinsic electrode wettability descriptors to operating parameters such as electrolyte flow rate and current. We first measure contact angles of water-organic product dilutions on polytetrafluoroethylene (PTFE) and graphite surfaces as planar analogues for GDE components. We then use material balances around the reactive gas-liquid-solid interface to calculate product mass fractions as functions of water sweep rate and current. Product composition maps visualize the extent to which changes in cell performance influence capillary pressure, a determinant of GDE saturation. Analyses suggest that formic acid mixtures pose little risk for GDE flooding across a wide range of conditions, but effluents containing <30% alcohol by mass may cause flooding. This study reveals opportunities to integrate microstructural features and oleophobic surface treatments into GDEs to repel aqueous-organic mixtures and expand the window of stable operating conditions.

25 ENERGY STORAGE↗
DOE OSTI2021

Resolving Anodic Current and Temperature Distributions in a Polymer Electrolyte Membrane Water Electrolysis Cell Using a Pseudo-Two-Phase Computational Fluid Dynamics Model

Expanding upon our prior experimental work, we constructed a three-dimensional model of a polymer electrolyte membrane water electrolyzer using computational fluid dynamics. We applied the assumption of pseudo-two-phase flow, the flow of two phases with equal velocity. Experimental data were used to obtain parameters and to determine the conditions under which this model was valid. Anodic distributions of current density, temperature, liquid saturation, and relative humidity were obtained at various flow rates. The overall current density and temperature difference from inlet to outlet at the anode agreed strongly with experimental measurements under most circumstances. This verification allowed us to further examine the apparent gas coverage calculated from experimental and model temperature data. Results suggested a low liquid saturation and low relative humidity at the anode due to the consumption of liquid water and water vapor. However, we questioned the accuracy of the pseudo-two-phase assumption at low water feed rates. We concluded that the model was applicable to systems with liquid water feed rates greater than 0.6 ml min -1 cm -2 . Therefore, it is a fair screening method that can advise which operating conditions lead to excessive temperatures or drying at the anode, thereby promoting the longevity of the membrane and catalyst.

25 ENERGY STORAGE↗
DOE OSTI2022

Finite Element Modeling of Electrochemical Polishing of Niobium in Hydrofluoric-Sulfuric Acid Electrolyte

Niobium (Nb) used in superconducting radio-frequency cavities requires smooth surface to achieve optimal performance. In this work, a finite element model that coupled electrochemistry, heat transfer, and fluid dynamics was developed to investigate the electrochemical polishing mechanisms of Nb, using experimentally measured polarization results of coupon samples as validations. The current and potential distribution, oxide growth kinetics of Nb in a complex cavity geometry was investigated as a function of temperature and coolant flow. A low temperature coolant with intermediate flow rate was found to reduce surface current and ensure oxide uniformity. These results could shed light on the design of future particle accelerators.

SRF accelerator cavity↗