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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 OSTI2024

Assessment of uranium nitride interatomic potentials

Uranium mononitride (UN) is a promising nuclear fuel due to its high fissile density, high thermal conductivity, and suitability for reprocessing. In this study, two uranium nitride interatomic potentials are assessed: Tseplyaev and Starikov's angular-dependent potential and Kocevski et al.'s embedded atom model potential. Predictions of the thermophysical and elastic properties of UN, UN 2 , and α- and β-U 2 N 3 computed using both potentials are assessed and compared to available experimental data. Notably, the Tseplyaev potential performs better with the energetic aspects of UN, e.g., specific heat capacity and point defect formation energies, whereas the Kocevski potential performs better with the structural aspects of UN, e.g., thermal expansion as well as with the elastic properties. The reasons why the Kocevski potential underestimates the UN specific heat are explained by examining the UN phonon properties modeled using both potentials. The Kocevski potential shows better identification of the mechanical stability ranges of UN, UN 2 , and α- and β-U 2 N 3 , reasonably predicting the melting point of UN and predicting stable structures for UN 2 and α- and β-U 2 N 3 . On the other hand, the Tseplyaev potential predicts a premature phase change of both UN and UN 2 and cannot stabilize α- nor β-U 2 N 3 . However, the Kocevski potential cannot predict a stable α-U phase and is thus not suitable for the calculation of formation energies for non-stoichiometric point defects.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

A high strength Al-2Ni-0.5Zr conductor alloy fabricated via laser powder bed fusion

There is a current need for new aluminum alloy design strategies to target applications requiring high strength and conductivity with reductions in mass. A new lightweight Al-2Ni-0.5Zr (wt. %) conductor alloy was fabricated using laser powder bed fusion. A design of experiments probed the alloy's solidification cracking susceptibility. It was observed that solidification cracking was generally reduced with fast scan speeds, above 1500 mm/s, and smaller hatch spacings. The different cooling rates throughout the melt pool produced a heterogeneous distribution of cellular and equiaxed Al 3 Ni precipitates in the as-printed alloy. Additionally, the rapid solidification characteristic of laser powder bed fusion created a super-saturated Zr solid solution. An aging heat treatment at 375 °C for 24 h imparted strengthening through the precipitation of L1 2 -Al 3 Zr nanoprecipitates, which counteracted the softening caused by the fragmentation and coarsening of Al 3 Ni precipitates. The yield strength increased from 138 MPa in the as-printed condition to 168 MPa after aging, while the ductility remained constant at ∼21%. The aging treatment simultaneously increased the electrical conductivity from 40.8% IACS (International Annealed Copper Standard) to 53.5% IACS. Modeling of the strengthening mechanisms and electrical conductivity contributions rationalized the simultaneous increase in strength and conductivity upon aging. Furthermore, the strengthening efficacy of the Al 3 Ni and L1 2 -Al 3 Zr precipitates, combined with the low Ni and Zr solubility in the FCC Al matrix, facilitated both high strength and electrical conductivity. Overall, the combination of strength and electrical conductivity positions this alloy as a suitable choice for additively manufactured lightweight conductors.

Additive manufacturing↗
DOE OSTI2021

Electronic thermal transport measurement in low-dimensional materials with graphene non-local noise thermometry

In low-dimensional systems, the combination of reduced dimensionality, strong interactions and topology has led to a growing number of many-body quantum phenomena. Thermal transport, which is sensitive to all energy-carrying degrees of freedom, provides a discriminating probe of emergent excitations in quantum materials and devices. However, thermal transport measurements in low dimensions are dominated by the phonon contribution of the lattice, requiring an experimental approach to isolate the electronic thermal conductance. In this work we measured non-local voltage fluctuations in a multi-terminal device to reveal the electronic heat transported across a mesoscopic bridge made of low-dimensional materials. Using two-dimensional graphene as a noise thermometer, we measured the quantitative electronic thermal conductance of graphene and carbon nanotubes up to 70 K, achieving a precision of ~1% of the thermal conductance quantum at 5 K. Employing linear and nonlinear thermal transport, we observed signatures of energy transport mediated by long-range interactions in one-dimensional electron systems, in agreement with a theoretical model.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Phenomena Identification and Ranking Tables for High Temperature Gas-Cooled Microreactors

Micro-scaled high-temperature gas-cooled reactors (micro-HTGRs) offer a promising option for reliable power in remote or off-grid locations. While the safety characteristics of modular HTGRs have been widely studied, a micro-HTGR configuration alters several key thermal-fluid phenomena that govern both normal operation and passive decay-heat removal. In many proposed concepts, the reactor vessel is oriented horizontally and integrated into an ISO shipping container to enhance transportability and modular deployment. This report documents a Phenomena Identification and Ranking Table (PIRT) exercise focused on the thermal hydraulic safety phenomena relevant to all micro-HTGRs. The objective is to systematically identify, describe, and rank the importance, uncertainty, and modeling complexity of the key phenomena that control core and vessel temperatures during normal operation, pressurized conduction cooldown (PCC), and depressurized conduction cooldown (with air ingress) conditions.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Can we safely go to 200 °C? An integrated approach to assessing impacts to the engineered barrier system in a high-temperature repository

Abstract. This presentation gives on overview of the complex thermo-hydro-mechanical-chemical (THMC) processes occurring during the disposal of heat-producing high-level radioactive waste in geologic repositories. A specific focus is on the role of compacted bentonite, which is commonly used as an engineered backfill material for emplacement tunnels because of its low permeability, high swelling pressure, and radionuclide retention capacity. Laboratory and field tests integrated with THMC modeling have provided an effective way to deepen our understanding of temperature-related perturbations in the engineered barrier system; however, most of this work has been conducted for maximum temperatures around 100 ∘C. In contrast, some international disposal programs have recently started investigations to understand whether local temperatures in the bentonite of up to 200 ∘C could be tolerated with no significant changes to safety relevant properties. Raising the maximum temperature is attractive for economical and safety reasons but faces the challenge of exposing the bentonite to significant temperature increases. Strong thermal gradients may induce complex moisture transport processes while geochemical processes, such as cementation and perhaps also illitization effects may occur, all of which could strongly affect the bentonite and near-field rock properties. Here, we present initial investigations of repository behavior exposed to strongly elevated temperatures. We will start discussing our current knowledge base for temperature effects in repositories exposed to a maximum temperature of 100 ∘C, based on data and related modeling analysis from a large heater experiment conducted for over 18 years in the Grimsel Test Site in Switzerland. We then show results from coupled THMC simulations of a nuclear waste repository in a clay formation exposed to a maximum temperature of 200 ∘C. We also explore preliminary data from a bench-scale laboratory mock-up experiment, which was designed to represent the strong THMC gradients occurring in a “hot” repository, and we finally touch on a full-scale field heater test to be conducted soon in the Grimsel Test Site underground research laboratory in Switzerland (referred to as HotBENT).

Birkholzer, Jens T. (ORCID:0000000279891912)↗
DOE OSTI2025

Role of Diurnal Cycle of Insolation on the MJO Propagation in the Maritime Continent

The diurnal cycle of convection in the Maritime Continent (MC) has been hypothesized to act as a barrier to the eastward propagation of the Madden‐Julian oscillation (MJO). To test this hypothesis, we use a regional model with realistic MJO to simulate an event from the boreal spring of 2013 that weakened and stalled over the MC. Two simulations are conducted: one that includes the diurnal cycle of insolation (CTL), and another without it (NO_DC). The MJO in the simulations was identified and tracked using a large‐scale precipitation tracking method that distinguishes propagation and non‐propagation unlike the usual Real‐time Multivariate MJO method. In the NO_DC simulation, the absence of diurnal heating reduces land precipitation, allowing more continuous eastward MJO propagation. An analysis of moist static energy budget reveals that MJO maintenance in NO_DC is due to increased longwave heating and reduced advection, whereas the persistent MJO propagation in NO_DC is due to increased advection and reduced longwave heating and surface latent heat flux. These processes, however, may vary across different parts of the MC, emphasizing the complexity of MJO propagation across the MC.

Zhou, Xin [National Center for Atmospheric Researc↗
DOE OSTI2021

Changes in precipitation and air temperature contribute comparably to permafrost degradation in a warmer climate

Abstract Surface energy budgets of high-latitude permafrost systems are poorly represented in Earth system models (ESMs), yet permafrost is rapidly degrading and these dynamics are critical to future carbon-climate feedback predictions. A potentially important factor in permafrost degradation neglected so far by ESMs is heat transfer from precipitation, although increases in soil temperature and thaw depth have been observed following increases in precipitation. Using observations and a mechanistic ecosystem model, we show here that increases in precipitation hasten active layer development beyond that caused by surface air warming across the North Slope of Alaska (NSA) under recent and 21st century climate (RCP8.5). Modeled active layer depth (ALD) in simulations that allow precipitation heat transfer agreed very well with observations from 28 Circumpolar Active Layer Monitoring sites (R 2 = 0.63; RMSE = 10 cm). Simulations that ignored precipitation heat transfer resulted in lower spatially-averaged soil temperatures and a 39 cm shallower ALD by 2100 across the NSA. The results from our sensitivity analysis show that projected increases in 21st century precipitation deepen the active layer by enhancing precipitation heat transfer and ground thermal conductivity, suggesting that precipitation is as important an environmental control on permafrost degradation as surface air temperature. We conclude that ESMs that do not account for precipitation heat transfer likely underestimate ALD rates of change, and thus likely predict biased ecosystem responses.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2024

Energy Requirements for Integration of Nuclear Reactors with Iron and Steel Plants

This report identifies energy needs of heavy energy users within the domestic iron and steel industry and suggests solutions for integrating nuclear energy. The iron and steel industry, composed of several types of plants which perform different processes with varied energy demands and vectors, is a heavy consumer of electric power and fossil fuels including coke and natural gas. Almost all major process temperatures exceed the temperatures of direct heat available from advanced reactors, and so electricity and hydrogen were considered instead. Reference units were adopted and estimated energy demands computed for the blast furnace (BF), direct reduced iron (DRI) unit, electric arc furnace (EAF), and reheat furnaces. By utilizing production capacity data from industry reports, the ranges of power demands were estimated, including for hydrogen production by high temperature steam electrolysis (HTSE). For the EAF and DRI unit, more detailed integration studies with thermodynamic modeling were also conducted and determined a possible solution with a specific reactor design and number of modules. Furthermore, because many unit processes are co-located, entire plants were considered by adding the energy demands of the unit processes to form four hypothetical reference plants. The range of power needs for the reference plants is compatible with multi-unit banks of microreactors at the low end, and would create a need for multiple larger-capacity SMRs at the high end (1 GWe plus 0.14 GWt). Although the overall power need at the high end is well-matched with one present-day large reactor offering (1.1 GWe), redundancy considerations may require a minimum of two reactors, potentially eliminating the single large reactor from consideration. Auxiliary or house loads would increase the reference plant estimates. Finally, the report provides total estimated energy needs under integration of all U.S. units of each process (BF, DRI, EAF, and reheat furnaces), representing a national potential for nuclear energy in the industry. U.S. iron and steel plants may be candidates for integration with nuclear reactors via electricity and hydrogen, and many sites have energy requirements that correspond well to the capacities of several advanced nuclear power designs.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Modeling the Joint Effects of Vegetation Characteristics and Soil Properties on Ecosystem Dynamics in a Panama Tropical Forest

Abstract In tropical forests, both vegetation characteristics and soil properties are important not only for controlling energy, water, and gas exchanges directly but also determining the competition among species, successional dynamics, forest structure and composition. However, the joint effects of the two factors have received limited attention in Earth system model development. Here we use a vegetation demographic model, the Functionally Assembled Terrestrial Ecosystem Simulator (FATES) implemented in the Energy Exascale Earth System Model (E3SM) Land Model (ELM), ELM‐FATES, to explore how plant traits and soil properties affect tropical forest growth and composition concurrently. A large ensemble of simulations with perturbed vegetation and soil hydrological parameters is conducted at the Barro Colorado Island, Panama. The simulations are compared against observed carbon, energy, and water fluxes. We find that soil hydrological parameters, particularly the scaling exponent of the soil retention curve ( B sw ), play crucial roles in controlling forest diversity, with higher B sw values (>7) favoring late successional species in competition, and lower B sw values (1 ∼ 7) promoting the coexistence of early and late successional plants. Considering the additional impact of soil properties resolves a systematic bias of FATES in simulating sensible/latent heat partitioning with repercussion on water budget and plant coexistence. A greater fraction of deeper tree roots can help maintain the dry‐season soil moisture and plant gas exchange. As soil properties are as important as vegetation parameters in predicting tropical forest dynamics, more efforts are needed to improve parameterizations of soil functions and belowground processes and their interactions with aboveground vegetation dynamics.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

An adaptive synchronous extraction (ASE) method for estimating intensity and footprint of surface urban heat islands: A case study of 254 North American cities

The urban heat island (UHI) effect has attracted great attention due to its potential impacts on rapidly growing urban areas. Using remotely sensed estimates of land surface temperature (LST), a large number of studies have focused on the surface UHI (SUHI) effect, which can be characterized by its two fundamental properties: intensity and footprint. The SUHI intensity reflects the LST difference between the urban area and the background reference area (BRA), and the SUHI footprint indicates the spatial extent influenced by the heat island. Currently, numerous methods have been developed to estimate the SUHI intensity and footprint, but are still greatly challenged by three main issues. Namely, the discrepancy in BRA selection criterion brings great uncertainty to the estimated SUHI intensity, the estimation of SUHI footprint is largely constrained by the predefined models, and the quantification of SUHI effect is potentially influenced by several confounding factors. Here, we proposed an adaptive synchronous extraction (ASE) method, which is capable of adaptively selecting the most optimal BRA while removing the influence of confounding factors, and achieving synchronous estimation of SUHI intensity and footprint. We applied the ASE method to 254 North American cities and conducted an in-depth comparative analysis to discuss its applicability and benefits. The main results include: (1) The ASE method avoids the limitations of existing methods in BRA selection and model presetting, and shows resilience to parameter variations. This makes the ASE method highly applicable to quantify the SUHI intensity and footprint in cities with various thermal characteristics. (2) The ASE method can better highlight the spatial, seasonal and day-night contrasts in the estimated SUHI intensity. This superiority is particularly evident when comparing it to methods based on the equal-area buffer or the simplified urban-extent algorithm. (3) Confounding factors pose non-negligible impacts on the quantification of the SUHI effect. Typically, ignoring the influence of topographic relief or missing LST data can lead to an overall overestimation of the SUHI intensity, while not removing surrounding urban areas will cause some underestimation of the SUHI intensity. In conclusion, overall, the proposed ASE method provides a new generalizable tool for quantifying the SUHI effect, which has great potentials for future studies and urban climate assessments.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Assessing Low-Temperature Geothermal Play Types: Relevant Data and Play Fairway Analysis Methods

The U.S. Department of Energy (DOE) Geothermal Technologies Office (GTO) is supporting the Geothermal Heating and Cooling Geospatial Datasets and Analysis project conducted by the National Renewable Energy Laboratory (NREL) as part of a broader effort to demonstrate the multi-faceted value of integrating geothermal power and geothermal heating and cooling (GHC) technologies into national decarbonization plans and community energy plans. Currently, there is a need to establish baseline low-temperature geothermal resource datasets and evaluate methods for deploying these technologies to provide the basis for supporting private sector investment. This project is focused on collecting baseline datasets, updating conceptual models, and creating Play Fairway Analysis (PFA) workflows for low-temperature (<150 degrees Celsius) geothermal resources of different geothermal play types (i.e., sedimentary basin, orogenic belts, and radiogenic geothermal play types) that could be used for geothermal heating and cooling (GHC), combined heat and power (CHP), and other geothermal direct uses (GDU) applications. Low-temperature geothermal resources are defined as reservoirs - natural or engineered - with temperatures <150 degrees Celsius. While the focus in the NREL effort is on GHC, resources at the upper end of this temperature range can also be used for small-scale power generation. This project does not include Ground Source Heat Pumps (GSHPs) technologies because they can be effectively developed almost anywhere. Low-temperature geothermal resources have not been studied as extensively as higher- to medium-temperature geothermal resources, but there is recent interest in improving understanding of these types of resources with an uptick of interest in geothermal technologies for decarbonizing heating and cooling systems. In addition, Enhanced Geothermal Systems (EGS) and other emerging technologies for exploiting petrothermal resources have opened the possibility of utilizing deep sedimentary basin systems, where porous media provide permeability and high temperatures can be reached at great depths. This project takes the approach of classifying low- temperature geothermal resources by geothermal play type (GPT). We defined and characterized three major classes of low-temperature GPT: sedimentary basins, orogenic systems, and radiogenic systems. We develop methodologies for evaluating and analyzing the potential for these resources building off the PFA approach to de-risking geothermal exploration and characterization. The proposed PFA approach for low-temperature geothermal resources includes: 1) identifying relevant data (e.g., datasets such bottom-hole temperatures from oil and gas wells, heat flow data, Quaternary faults and stress field data, geophysical data, etc.); 2) grouping and weighting of relevant datasets into PFA criteria (e.g., geological, risk, and economic criteria); 3) uncertainty quantification; 4) developing favorability or common risk maps for low-temperature geothermal resources to identify potential locations for more focused data collection; and 5) estimating electric power generation and heating potential at those locations using the GeoRePORT Resource Size Assessment Tool (RSAT). This project should facilitate future deployment of GHC, CHP, and GDU by providing data, tools, and a workflow applicable to low-temperature geothermal resources. Increased deployment of GHC and GDU will help achieve national and local decarbonization goals.

15 GEOTHERMAL ENERGY↗
DOE OSTI2026

Radiative Cooling Paints: Application on Warehouses and Integration with Phase Change Materials

Despite extensive research on radiative cooling (RC), researchers are still working to understand its best implementation strategy and potential benefits. Understanding this could be an instrumental part of reducing building energy costs and combating climate change. In this work, we introduce two concepts to achieve this goal and broaden the application of RC paints. While building energy simulations for RC are common, most studies focus on single-layer paints in residential settings. Limited research exists on warehouses, and no literature has conducted multi-climate zone analyses or included RC technologies with >90% reflectance. As RC technology advances in efficiency, versatility, and affordability, large-scale simulations across diverse climates are crucial, particularly for warehouses as a passive indoor temperature control solution. Here, a TRNSYS-modeled single-story warehouse assesses the energy impact of BaSO4-based RC paints. Another under-explored RC application is its integration with phase change materials (PCMs), which provide thermal regulation via latent heat storage. Though RC and PCMs have been combined by placing PCMs atop, beneath, or within RC layers, studies focus on either experiments or modeling, with no validation between the two. Here, we develop a simple RC+PCM experimental and modeling setup, placing RC paint atop an aluminum cell filled with a Rubitherm PCM.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Single Primary Heat Extraction and Removal Emulator (SPHERE) Long Duration Testing

For the development of heat-pipe cooled microreactors, it is crucial to thoroughly understand the characteristics and functioning of heat pipes across a wide spectrum of operating conditions. Passive heat removal and its long-term performance stability are critical factors in this context. Enhanced experimental data is vital for evaluating the operational lifespan of alkali metal heat pipes. Idaho National Laboratory (INL) has successfully conducted an extended duration test on a high-performance sodium-filled heat pipe, closely monitoring the axial temperature profile, power supplied by the heaters, and heat removed by a gas-gap calorimeter. The results from this testing provide valuable data that are instrumental in supporting heat pipe validation efforts. Specifically, this data aids in the development and validation of Sockeye, the Multiphysics Object-Oriented Simulation Environment (MOOSE) tool under the US-DOE NEAMS program designed for heat pipe modeling. By comparing experimental results with Sockeye’s predictions, the tool's accuracy and reliability can be assessed and improved, thereby enhancing its capability to simulate heat pipe operations under various conditions.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

3D modelling of MHD mixed convection flow in a vertical duct with transverse magnetic field and volumetric or surface heating

Understanding phenomena associated with the multiple effects/interactions of the fusion nuclear environment on liquid metal flow is required to correctly design liquid metal (LM) blankets for fusion facilities. These effects are investigated in the present work by numerically simulating 3D LM MHD flow. The simulated geometry consists of a straight, vertical duct which runs perpendicular to a strong, fringing applied magnetic field. There is also a region of applied heating as the primary goal is to explore buoyancy effects in MHD duct flows. Results are presented for both buoyancy assisted (upwards) and buoyancy opposed (downwards) flows in conducting and insulating ducts for a range of Hartmann numbers (Ha) up to 100, Reynolds numbers (Re) from 10 3 to 10 4 and Grashof (Gr) numbers from 10 7 to 10 8 . While increasing Gr or decreasing Re increases buoyancy effects, increasing Ha was shown to increase maximum temperature through turbulence reduction. The extent to which the MHD mixed convection flows are quasi-2D is analyzed and buoyant effects, in competition with electromagnetic forces, are shown to bring about 3D flow features not seen in purely MHD flows. Volumetric nuclear heating with steep gradients is applied to the vertical MHD flows for comparison to flows with surface heating only. Finally, surface heating generates stronger buoyancy effects than volumetric heating of the same total power; however, many of the same phenomena occur. Therefore, surface heating, the only option for lab experiments, can provide indication of the effects of volumetric heating in MHD flows.

42 ENGINEERING↗
DOE OSTI2026

Structural coherence model for predicting molten salt thermal conductivity informed by the pair distribution function

To enable thermal behavior prediction and design optimization of molten salt reactors, thermal conductivity of molten salts must be characterized in terms of salt composition and temperature. Current theoretical models fail to provide consistent approximations for all halide mixtures, particularly actinide-bearing melts. This study aims to link the short-range order structure of molten salts to the mean free path of energy carriers through a simple structural coherence model informed by the partial pair distribution function. The proposed method is used to predict the thermal conductivity of 33 alkali and alkaline earth halide salts. Predictions approximate experimental measurements with a mean absolute error of 15.7% for dissociating, complexing, and actinide salts, including unary LiCl, NaCl, and MgCl 2 as well as mixtures LiF–NaF–KF (FLiNaK), LiF–BeF 2 (FLiBe), and NaCl–UCl 3 . The work provides evidence for the validity of energy carrier descriptions of molecular-level heat transfer in molten salts, with implications for improved theories of liquid energy transport in general.

Actinide mixtures↗
DOE OSTI2022

Giant Isotope Effect of Thermal Conductivity in Silicon Nanowires

Isotopically purified semiconductors potentially dissipate heat better than their natural, isotopically mixed counterparts as they have higher thermal conductivity (κ). But the benefit is low for Si at room temperature, amounting to only ~10% higher κ for bulk 28 Si than for bulk natural Si ( nat Si). Here we show that in stark contrast to this bulk behavior, 28 Si (99.92% enriched) nanowires have up to 150% higher κ than nat Si nanowires with similar diameters and surface morphology. Using a first-principles phonon dispersion model, this giant isotope effect is attributed to a mutual enhancement of isotope scattering and surface scattering of phonons in nat Si nanowires, correlated via transmission of phonons to the native amorphous SiO 2 shell. The Letter discovers the strongest isotope effect of κ at room temperature among all materials reported to date and inspires potential applications of isotopically enriched semiconductors in microelectronics.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Improving Cost and Efficiency of the Scalable Solid Oxide Fuel Cells Power System

The objective of this project was to design and develop a 20kW range small-scale solid oxide fuel cells (SOFC) power system for applications such as data centers and commercial buildings. The original plan included a 5,000 hours demonstration and a Techno-Economic Analysis (TEA) which were dropped as part of project termination. The original project plan was to use a stack with a cross-flow cell design which had previously been tested for 500 hours at a community college in Malta, NY. However, it was decided to move to the advanced R-SOFC co-flow cell developed under Department of Energy Award DE-FE0031971. The advanced cell design has the advantage of a larger active area for the same manufacturing footprint which results in fewer required cells for the same stack power, hence a higher volumetric power density (kW/L) and lower cost per kW than the original cross-flow cell design. A full SOFC system Simulink model was developed and calibrated with testing data from a fuel cell stack and BOP (balance of plant) components. The simulation results from the calibrated model showed an acceptable match with the experimental data. A structural analysis conducted for various load scenarios indicated no high stress areas for all spatial directions. Major electrical system components were acquired, built and successfully tested. System sensors were verified and validated against controls. Safety checks, a diagnostic check, PID tuning, and control software commissioning tasks were also conducted. The power electronics prototype was delivered and trial testing completed. Balance of Plant component testing and simulation work was conducted to characterize Reformer-Heat Exchanger heat transfer and backpressure and reformer catalyst methane conversion and product selectivity. Simulations were conducted to design the Anode and Cathode fluid passages and size the air-air and fuel-fuel heat exchangers. A Burner operation map was created from test data and the Anode Gas Recirculation blower was tested to evaluate its durability. The SOFC system used a horizontal style design where components sit directly on a casting with a direct connection to the skid. This design has efficient packaging and a small footprint with approximate dimensions of 750 mm x 700 mm x 1700 mm. An SOFC system was built and successfully tested at the Malta, NY facility The system for over 500 hours under load of which over 300 hours was at full load of 20 kW.

30 DIRECT ENERGY CONVERSION↗