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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 91 records · Page 5
All sourcesNASA NTRSDOE OSTI
DOE OSTI2019

Carbon Dioxide Adsorption via Ultra-High Surface Area Carbon

In this Phase 1 project, Vuronyx Technologies investigated the use of a high surface area carbon for adsorption of carbon dioxide. Current industry practice of CO 2 capture is by using amine-based scrubbing systems via absorption–regeneration technology. The amine solvent binds with the CO 2 generated during coal combustion in the absorption reactor, and is sent to a stripper column for solvent regeneration and recycling. The separated CO 2 is then cooled and transported for compression and sequestration. Amine based CO 2 removal is energy intensive and not costeffective due to the energy penalty associated with the stripping of CO 2 and regeneration of solvent.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2014

Cooling Strategies for Vane Leading Edges in a Syngas Environment Including Effects of Deposition and Turbulence

The Department of Energy has goals to move land based gas turbine systems to alternate fuels including coal derived synthetic gas and hydrogen. Coal is the most abundant energy resource in the US and in the world and it is economically advantageous to develop power systems which can use coal. Integrated gasification combined cycles are (IGCC) expected to allow the clean use of coal derived fuels while improving the ability to capture and sequester carbon dioxide. These cycles will need to maintain or increase turbine entry temperatures to develop competitive efficiencies. The use of coal derived syngas introduces a range of potential contaminants into the hot section of the gas turbine including sulfur, iron, calcium, and various alkali metals. Depending on the effectiveness of the gas clean up processes, there exists significant likelihood that the remaining materials will become molten in the combustion process and potentially deposit on downstream turbine surfaces. Past evidence suggests that deposition will be a strong function of increasing temperature. Currently, even with the best gas cleanup processes a small level of particulate matter in the syngas is expected. Consequently, particulate deposition is expected to be an important consideration in the design of turbine components. The leading edge region of first stage vanes most often have higher deposition rates than other areas due to strong fluid acceleration and streamline curvature in the vicinity of the surface. This region remains one of the most difficult areas in a turbine nozzle to cool due to high inlet temperatures and only a small pressure ratio for cooling. The leading edge of a vane often has relatively high heat transfer coefficients and is often cooled using showerhead film cooling arrays. The throat of the first stage nozzle is another area where deposition potentially has a strongly adverse effect on turbine performance as this region meters the turbine inlet flow. Based on roughness levels found on in service vanes (Bons, et al., 2001, up to 300 microns) flow blockage in first stage turbine nozzles can easily reach 1 to 2 percent in conventional turbines. Deposition levels in syngas fueled gas turbines are expected to be even more problematic. The likelihood of significant deposition to the leading edge of vanes in a syngas environment indicates the need to examine this effect on the leading edge cooling problem. It is critical to understand the influence of leading edge geometry and turbulence on deposition rates for both internally and showerhead cooled leading edge regions. The expected level of deposition in a vane stagnation region not only significantly changes the heat transfer problem but also suggests that cooling arrays may clog. Addressing the cooling issue suggests a need to better understand stagnation region heat transfer with realistic roughness as well as the other variables affecting transport near the leading edge. Also, the question of whether leading edge regions can be cooled internally with modern cooling approaches should also be raised, thus avoiding the clogging issue. Addressing deposition in the pressure side throat region of the nozzle is another critical issue for this environment. Issues such as examining the protective effect of slot and full coverage discrete-hole film cooling on limiting deposition as well as the influence of roughness and turbulence on effectiveness should be raised. The objective of this present study is to address these technical challenges to help enable the development of high efficiency syngas tolerant gas turbine engines.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2014

Project Entitled "Developing a Mobile Torrefaction Machine" (STTR Phase 1 Final Technical Report)

The goal of this project, sponsored by Agri-Tech Producers, LLC (ATP), the small business grantee, was to determine if the torrefaction technology, developed by North Carolina State University (NCSU), which ATP has licensed, could be feasibly deployed in a mobile unit. The study adds to the area investigated, by having ATP’s STTR Phase I team give thoughtful consideration to how to use NCSU’s technology in a mobile unit. The findings by ATP’s team were that NCSU’s technology would best perform in units 30’ by 80’ (See Spec Sheet for the Torre-Tech 5.0 Unit in the Appendix) and the technical effectiveness and economic feasibility investigation suggested that such units were not easily, efficiently or safely utilized in a forest or farm setting. (Note rendering of possible mobile system in the Appendix) Therefore, the findings by ATP’s team were that NCSU’s technology could not feasibly be deployed as a mobile unit.

09 BIOMASS FUELS↗
DOE OSTI2014

Beneficial Use of Carbon Dioxide in Precast Concrete Production

The feasibility of using carbon dioxide as feedstock in precast concrete production is studied. Carbon dioxide reacts with calcium compounds in concrete, producing solid calcium carbonates in binding matrix. Two typical precast products are examined for their capacity to store carbon dioxide during the production. They are concrete blocks and fiber-cement panels. The two products are currently mass produced and cured by steam. Carbon dioxide can be used to replace steam in curing process to accelerate early strength, improve the long-term durability and reduce energy and emission. For a reaction within a 24-hour process window, the theoretical maximum possible carbon uptake in concrete is found to be 29% based on cement mass in the product. To reach the maximum uptake, a special process is developed to promote the reaction efficiency to 60-80% in 4-hour carbon dioxide curing and improve the resistance to freeze-thaw cycling and sulfate ion attack. The process is also optimized to meet the project target of $10/tCO 2 in carbon utilization. By the use of self-concentrating absorption technology, high purity CO 2 can be produced at a price below $40/t. With low cost CO 2 capture and utilization technologies, it is feasible to establish a network for carbon capture and utilization at the vicinity of carbon sources. If all block produces and panel producers in United States could adopt carbon dioxide process in their production in place of steam, carbon utilization in these two markets alone could consume more than 2 Mt CO 2 /year. This capture and utilization process can be extended to more precast products and will continue for years to come.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Eastern Renewable Generation Integration Study

The Eastern Interconnection (EI) is one of the largest power systems in the world, and its size and complexity have historically made it difficult to study in high levels of detail in a modeling environment. In order to understand how this system might be impacted by high penetrations (30% of total annual generation) of wind and solar photovoltaic (PV) during steady state operations, the National Renewable Energy Laboratory (NREL) and the U.S. Department of Energy (DOE) conducted the Eastern Renewable Generation Integration Study (ERGIS). This study investigates certain aspects of the reliability and economic efficiency problem faced by power system operators and planners. Specifically, the study models the ability to meet electricity demand at a 5-minute time interval by scheduling resources for known ramping events, while maintaining adequate reserves to meet random variation in supply and demand, and contingency events. To measure the ability to meet these requirements, a unit commitment and economic dispatch (UC&ED) model is employed to simulate power system operations. The economic costs of managing this system are presented using production costs, a traditional UC&ED metric that does not include any consideration of long-term fixed costs. ERGIS simulated one year of power system operations to understand regional and sub-hourly impacts of wind and PV by developing a comprehensive UC&ED model of the EI. In the analysis, it is shown that, under the study assumptions, generation from approximately 400 GW of combined wind and PV capacity can be balanced on the transmission system at a 5-minute level. In order to address the significant computational burdens associated with a model of this detail we apply novel computing techniques to dramatically reduce simulation solve time while simultaneously increasing the resolution and fidelity of the analysis. Our results also indicate that high penetrations of wind and PV (collectively variable generation (VG)), significantly impact the operation of traditional generating resources and cause these resources to be used less frequently and operate across a broader output range because wind and PV have lower operating costs and variable output levels.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2024

Carbon Ores-Derived Critical Materials for Clean Energy Technology Applications

Presented at the 48th International Technical Conference on Clean Energy (Clearwater Clean Energy Conference), Clearwater, Florida, June 16-19, 2024. This presentation describes the Energy & Environmental Research Center’s development of the Upgraded Carbon Ores-to-Products (UCOP) technology to produce high‑quality graphite and other critical materials from coal and coal wastes for clean energy applications such as batteries and electrodes. It outlines the technical approach, including feedstock cleaning, controlled heat treatment, and graphitization, and presents results demonstrating high graphite purity, novel microstructures, and competitive performance relative to commercial graphite. The work highlights the potential for lower environmental impact and domestic supply chains for critical materials amid increasing global demand and supply‑chain constraints.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2014

Micro-Structured Sapphire Fiber Sensors for Simultaneous Measurements of High-T and Dynamic Gas Pressure in Harsh Environments

This is the final report for the program “Micro-Structured Sapphire Fiber Sensors for Simultaneous Measurements of High Temperature and Dynamic Gas Pressure in Harsh Environments”, funded by NETL, and performed by Missouri University of Science and Technology, Clemson University and University of Cincinnati from October 1, 2009 to September 30, 2014. Securing a sustainable energy economy by developing affordable and clean energy from coal and other fossil fuels is a central element to the mission of The U.S. Department of Energy’s (DOE) National Energy Technology Laboratory (NETL). To further this mission, NETL funds research and development of novel sensor technologies that can function under the extreme operating conditions often found in advanced power systems. The main objective of this research program is to conduct fundamental and applied research that will lead to successful development and demonstration of robust, multiplexed, microstructured silica and single-crystal sapphire fiber sensors to be deployed into the hot zones of advanced power and fuel systems for simultaneous measurements of high temperature and gas pressure. The specific objectives of this research program include: 1) Design, fabrication and demonstration of multiplexed, robust silica and sapphire fiber temperature and dynamic gas pressure sensors that can survive and maintain fully operational in high-temperature harsh environments. 2) Development and demonstration of a novel method to demodulate the multiplexed interferograms for simultaneous measurements of temperature and gas pressure in harsh environments. 3) Development and demonstration of novel sapphire fiber cladding and low numerical aperture (NA) excitation techniques to assure high signal integrity and sensor robustness.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2018

Final Technical Report

In September 2010, RTI and the DOE/NETL signed a cooperative agreement (DE-FE000489) to design, build, and operate a pre-commercial syngas cleaning system that would capture up to 90% of the CO 2 in the syngas slipstream, and demonstrate the ability to reduce syngas contaminants to meet DOE’s specifications for chemical production application. This pre-commercial syngas cleaning system is operated at Tampa Electric Company’s (TEC) 250-MWe integrated gasification combined cycle (IGCC) plant at Polk Power Station (PPS), located near Tampa, Florida. The syngas cleaning system consists of the following units: Warm Gas Desulfurization Process (WDP) - this unit processes a syngas flow equivalent of 50 MWe of power (50 MWe equivalent corresponds to about 2.0 MM scfh of syngas on dry basis) to produce a desulfurized syngas with a total sulfur (H 2 S+COS) concentration ~ 10 ppmv. Water Gas Shift (WGS) Reactor - this unit converts sufficient CO into CO 2 to enable 90% capture of the CO 2 in the syngas slipstream. This reactor uses conventional commercial shift catalyst technologies. Low Temperature Gas Cooling (LTGC) - this unit cools the syngas for the low temperature activated MDEA process and separates any condensed water. Activated MDEA Process (aMDEA) - this unit employs a non-selective separation for the CO 2 and H 2 S present in the raw syngas stream. Because of the selective sulfur removal by the upstream WDP unit, the CO 2 capture target of 90% CO 2 can be achieved with the added benefit that total sulfur concentration in the CO 2 product is < 100 ppmv. An additional advantage of the activated MDEA process is that the non-selective sulfur removal from the treated syngas reduces sulfur in the treated gas to very low sub-ppmv concentrations, which are required for chemical production applications. Testing to date of this pre-commercial syngas cleaning system has shown that the technology has great potential to provide clean syngas from coal and petcoke-based gasification at increased efficiency and at significantly lower capital and operating costs than conventional syngas cleanup technologies. However, before the technology can be deemed ready for scale-up to a full commercial-scale demonstration, additional R&D testing is needed at the site to address the following critical technical risks: WDP sorbent stability and performance; Impact of WDP on downstream cleanup and conversion steps; Metallurgy and refractory; Syngas cleanup performance and controllability; Carbon capture performance and additional syngas cleanup The proposed plan to acquire this additional R&D data involves: Operation of the units to achieve an additional 3,000 hours of operation of the system within the performance period, with a target of achieving 1,000 hours of those hours via continuous operation of the entire integrated pre-commercial demonstration system; Rapid turnaround of repairs and/or modifications required as necessary to return any specific unit to operating status with documentation and lessons learned to support technology maturation, and; Proactive performance of maintenance activities during any unplanned outages and if possible while operating.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1982

Gas turbine critical research and advanced technology (CRT) support project

The technical progress to provide a critical technology base for utility gas turbine systems capable of burning coal-derived fuels is summarized. Project tasks include the following: (1) combustion - to investigate the combustion of coal-derived fuels and the conversion of fuel-bound nitrogen to NOx; (2) materials - to understand and prevent the hot corrosion of turbine hot section materials; and (3) system studies - to integrate and guide the technological efforts. Technical accomplishments include: an extension of flame tube combustion testing of propane - Toluene Fuel Mixtures to vary H2 content from 9 to 18 percent by weight and the comparison of results with that predicted from a NASA Lewis General Chemical Kinetics Computer Code; the design and fabrication of combustor sector test section to test current and advanced combustor concepts; Testing of Catalytic combustors with residual and coal-derived liquid fuels; testing of high strength super alloys to evaluate their resistance to potential fuel impurities using doped clean fuels and coal-derived liquids; and the testing and evaluation of thermal barrier coatings and bond coatings on conventional turbine materials.

Furman, E. R.↗
DOE OSTI2020

Economic Extraction and Recovery of REEs and Production of Clean Value-Added Products from Low-Rank Coal Fly Ash

The University of North Dakota (UND) Energy & Environmental Research Center (EERC) teamed with Pacific Northwest National Laboratory (PNNL) , the North Dakota Industrial Commission Lignite Research Program, and commercial partners Basin Electric Power Cooperative, Great River Energy, and Southern Company to execute a Cooperative Agreement funded by the U.S. Department of Energy’s (DOE’s) National Energy Technology Laboratory (NETL) focused on identifying unique pathways and pretreatments to extract rare-earth elements (REEs) from low-rank coal (LRC) ash in a more economical and environmentally benign manner than current methods. The EERC drew upon the unique and deep knowledge of the team regarding LRC geochemistry, ash transformation mechanisms during combustion, and fly ash chemistry in the approach to understand the portioning of REEs in LRC ash. A comprehensive characterization effort was undertaken to fully establish the form, associations, and partitioning of the REEs and other elements/minerals of interest in fly ash, as well as the ash chemistry, mineralogy, and morphology. Using this information, the team tested methods of REE extraction to take advantage of the unique and advantageous properties of LRC ash. Multiple complementary approaches were evaluated that combined both novel and proven methods to develop an extractive process for REEs and other high-value metals from LRC ash that provide technological and economic progress on the current state of the art. Methodologies were also evaluated for the potential to synergistically remove toxic metals while extracting other high-value metals from the ash, generating a clean, safe ash material as a value-added product. This would eliminate waste and offer significant additional revenue potential. Based on laboratory-scale testing, an initial high-level technical and economic analysis to estimate operating expenses and product revenues to guide future phases of technology development was implemented. By focusing on minimizing process steps and consumptive use of extraction solutions, a tunable, economically viable process for REE extraction from LRC ash was developed. The tunable process has the ability to be adjusted to adapt to the differing ash chemical and physical properties that are characteristic of LRC ash. This is key to deployment as a commercial process. In demonstrating the process, the EERC was able to illustrate mixed REE concentration greater than the goal of 2 wt%. High-level economic analysis of the process with LRC ash of moderate REE levels demonstrated the potential of the process, but recovery of just the REEs was insufficient to cover operational costs. With the additional extraction of other high-value metals found in LRC ash, the process economics approach would break even, and it is anticipated that with process optimization, the developed process could potentially be economically sound. The same economic analysis performed utilizing LRC ash with high levels of REEs showed the recovery of the REEs alone would make the process economically viable even without further optimization.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

Economic Extraction and Recovery of REEs and Production of Clean Value-Added Products from Low-Rank Coal Fly Ash

TechConnect World Innovation Conference & Expo, Washington, DC, June 13–15, 2022. The University of North Dakota (UND) Energy & Environmental Research Center (EERC) teamed with Pacific Northwest National Laboratory; the North Dakota Industrial Commission Lignite Research Program; and commercial partners Basin Electric Power Cooperative, Great River Energy, and Southern Company to execute a Cooperative Agreement funded by the U.S. Department of Energy’s National Energy Technology Laboratory (NETL) focused on identifying unique pathways and pretreatments to extract rare-earth elements (REEs) from low-rank coal (LRC) ash in a more economical and environmentally benign manner than current methods. By focusing on minimizing process steps and consumptive use of extraction solutions, a tunable, economically viable process for REE extraction from LRC ash was developed.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2014

Final Report for contract DE-SC0010151, "A Cost-Effective Oxygen Separation System Based on Open Gradient Magnetic Field by Polymer Beads"

At present much of the oxygen enrichment market is based primarily on cryogenic systems, ion transport membranes made of ceramics, or polymer membranes technologies. All these methods have some positive and some negative attributes, but remain too expensive for the cost effective production of pure oxygen needed for clean renewable energy conversion projects. In a very successful Phase I period, the ITN-TAMU team accomplished the completion of most of the sub-tasks on oxygen separation based on our proposed magnetic field gradients. Theoretical and computer simulation data under different conditions of flow rates, magnetic flux, magnetic beads packing density, pressure and temperature have resulted very valuable observations. Chitosan based polymer magnetic beads showed the best results for uniformity and column packing. Due to limited magnetic force of 1 Tesla, we were restricted to use only single small column of magnetic beads and limited air pressure with controlled flow rate. We also fabricated smaller sized beads column with metal and clear plastic frames to be used for more concentrated packed capacity. Beads made with rare earth Neodymium were not uniform and were quite brittle. Different surfactants have minimized the effect of the de-aggregation of polymer magnetic beads. This Phase I development work also included overcoming key packaging hurdles such as high packing capacity of magnetic polymer beads and formation of consistent batch of magnetic beads. Market and commercialization studies were also initiated to show that there is a growing market for the proposed cost-effective oxygen separation system for energy conversion projects.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2016

FutureGen 2.0 Oxy-combustion Large Scale Test – Final Report

The primary objectives of the FutureGen 2.0 CO 2 Oxy-Combustion Large Scale Test Project were to site, permit, design, construct, and commission, an oxy-combustion boiler, gas quality control system, air separation unit, and CO 2 compression and purification unit, together with the necessary supporting and interconnection utilities. The project was to demonstrate at commercial scale (168MWe gross) the capability to cleanly produce electricity through coal combustion at a retrofitted, existing coal-fired power plant; thereby, resulting in near-zeroemissions of all commonly regulated air emissions, as well as 90% CO 2 capture in steady-state operations. The project was to be fully integrated in terms of project management, capacity, capabilities, technical scope, cost, and schedule with the companion FutureGen 2.0 CO 2 Pipeline and Storage Project, a separate but complementary project whose objective was to safely transport, permanently store and monitor the CO 2 captured by the Oxy-combustion Power Plant Project. The FutureGen 2.0 Oxy-Combustion Large Scale Test Project successfully achieved all technical objectives inclusive of front-end-engineering and design, and advanced design required to accurately estimate and contract for the construction, commissioning, and start-up of a commercial-scale "ready to build" power plant using oxy-combustion technology, including full integration with the companion CO 2 Pipeline and Storage project. Ultimately the project did not proceed to construction due to insufficient time to complete necessary EPC contract negotiations and commercial financing prior to expiration of federal co-funding, which triggered a DOE decision to closeout its participation in the project. Through the work that was completed, valuable technical, commercial, and programmatic lessons were learned. This project has significantly advanced the development of near-zero emission technology and will be helpful to plotting the course of, and successfully executing future large demonstration projects. This Final Scientific and Technical Report describes the technology and engineering basis of the project, inclusive of process systems, performance, effluents and emissions, and controls. Further, the project cost estimate, schedule, and permitting requirements are presented, along with a project risk and opportunity assessment. Lessons-learned related to these elements are summarized in this report. Companion reports Oxy-combustion further document the accomplishments and learnings of the project, including: A.01 Project Management Report which describes what was done to coordinate the various participants, and to track their performance with regard to schedule and budget B.02 Lessons Learned - Technology Integration, Value Improvements, and Program Management, which describes the innovations and conclusions that we arrived upon during the development of the project, and makes recommendations for improvement of future projects of a similar nature . B.03 Project Economics, which details the capital and operation costs and their basis, and also illustrates the cost of power produced by the plant with certain sensitivities. B.04 Power Plant, Pipeline, and Injection Site Interfaces, which details the interfaces between the two FutureGen projects B.05 Contractual Mechanisms for Design, Construction, and Operation, which describes the major EPC, and Operations Contracts required to execute the project.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

A Comprehensive Economic Coal Transition in South Asia

Many countries are considering accelerating their coal transition. A coal transition refers to an energy sector’s shift from a reliance on coal toward an energy mix largely based on cleaner fuels and renewable energy sources. Such a transition is not just related to greenhouse gas emissions, but also encompasses a range of benefits, recognizing that global energy costs and options are changing. Since 2015, proposed new coal power capacity has dropped by three-quarters globally, leaving only a few countries that develop coal-fired power plants at scale (Littlecott et al., 2021). Historic steps were taken at the United Nations Climate Change 26th Conference of Parties (COP26) in Glasgow, as countries pledged to stop new coal builds, end international coal financing, phase down and phase out unabated coal use, and transition to clean energy. In South Asia, there have been several indicators suggesting that countries may be open to moving toward a coal transition. For example, the number of coal power plants under development across South Asia has decreased by 87% since 2015 (Littlecott et al., 2021). However, the challenges of assuring a just transition are substantial. Because coal plays a critical role in the energy and economic systems in South Asia, especially India, moving away from coal means realizing a broader country-wide economic and social transition. A comprehensive, integrated transition strategy for each state is thus needed urgently. This report briefly reviews the current trends and policies on coal in South Asian countries, develops a framework for a comprehensive economic coal transition, and assesses the opportunities and challenges of the transition in key countries. Several important findings emerge from the analysis. First, a coal transition can support overall economic growth and stability. Financial advantages to a well-planned coal transition include mitigating the risk of stranded assets and taking advantage of low-cost renewables. As a global coal transition proceeds, funds are being diverted from new unabated coal power plants, and utilization rates are declining. The likelihood that coal assets will become stranded is increasing, and the potential for future losses therefore increases as well. Second, coal imports in South Asia are rising. Of the coal consumed in Bangladesh, India, Nepal, and Sri Lanka, 32% is imported; this number increases to 94% when excluding India (International Energy Agency [IEA], 2021d). This illustrates a serious energy security risk. One example is the recent increase in coal prices in South Asia, to be discussed in Section 2.2.1. A diverse energy portfolio that incorporates local renewable energy can provide resilience in the face of changing commodity prices and availability. Third, the social benefits of a coal transition include positive health impacts and broader economic improvements in job creation, although assuring a just transition may be a challenge. Phasing out or phasing down coal can significantly reduce air pollutant emissions and therefore minimize associated premature mortality and improve life expectancy. Additional societal benefits of a coal transition include the high economy-wide potential for job creation, although it creates challenges in terms of reintegration and resettlement for coal miners and their communities.

01 COAL, LIGNITE, AND PEAT↗