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At least 91 records · Page 5

All sources NASA NTRS DOE OSTI

DOE OSTI2024

High performance heat exchangers for next generation hybrid cooler (CRADA Final Report)

The evaporative cooling process has been successfully deployed in multiple energy conversion processes such as power generation, process cooling, heating, ventilation & cooling (HVAC), and commercial and industrial refrigeration. The heat exchanger is a very common yet extremely critical component of such systems. The device is important since the performance of the overall cooling system heavily relies on the thermal-hydraulic efficiency of the heat exchanger. The possible wet operation as evaporative cooling heat exchanger complicates the issue. Indeed, based on the hybrid nature of operation (fully dry, partially wet, fully wet) the efficiency can vary significantly and can cause performance variation for the whole system. Understanding the importance of the issue, Oak Ridge National Laboratory (Contractor) and Baltimore Aircoil Company (Participant) propose an activity focused on the analysis of the existing heat exchanger technology used in air and evaporative cooling processes and design, development and demonstration of a novel heat exchanger design based on porous materials. The potential candidates include metallic wire meshes and metal foams carefully designed for the proposed application. Prior research has indicated that these materials have great potential for deployment in thermal systems, particularly heat sinks and heat exchangers. It is expected that the successful completion of the project will lead to novel heat exchanger technology for hybrid systems (capable of dry and wet operation) by exploring newly emerging materials and their potential for heat transfer application. The overall goal is to develop a next generation heat exchanger technology which can be deployed in evaporative cooling systems. The impact of the such development is significant since, it will not only make the overall system highly efficient but will also, reduce the total refrigerant charge in the heat exchanger, a critical aspect for the deployment of refrigerants with lower Global Warming Potential (GWP).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

Method for the generation of power

Disclosed herein is a method comprising heating a strontium-containing compound using radiation in a first reactor; decomposing the strontium-containing compound into an oxide and carbon dioxide as a result of heat generated by the exposure to the radiation; reacting the oxide and the carbon dioxide in a second reactor; where the oxide and carbon dioxide react to produce heat; heating a working fluid using the heat produced in the second reactor; and driving a turbine with the heated working fluid to generate energy. Disclosed herein too is a composition comprising strontium carbonate; and strontium zirconate; where the mass ratio of strontium carbonate to strontium zirconate 2:8 to 8:2.

Klausner, James F.↗

DOE OSTI2022

Polymer film heat exchanger sealing system and method

A method of manufacturing a heat exchanger array that includes stacking a plurality of heat exchanger units in an aligned configuration with respective first ports of the plurality of heat exchanger units aligned. The method can further include generating heat in the first coupling elements at the same time and at a temperature sufficient to generate a first plurality of respective couplings between adjacent sheets of adjacent heat exchanger units about adjacent first ports and without a coupling being generated between the first and second sheets of a given heat exchanger unit.

Rutkowski, Adam↗

DOE OSTI2021

Fourier-like Thermal Relaxation of Nanoscale Explosive Hot Spots

Hot spots are local regions of high temperature that are widely considered to govern explosive initiation. Hot spot dynamics rests on a delicate balance between heat generation due to chemical reactions and heat loss through thermal conduction, making accurate determinations of the conductivity under extreme conditions a key component of predictive explosive models. We develop here an approach to directly determine the thermal transport properties of explosive hot spots with realistic initial structures through a combination of molecular dynamics (MD) and diffusive heat equation (HEq) modeling. Effective thermal conductivity values are determined by fitting HEq models to MD predictions of long timescale hot spot relaxation. The approach is applied to model hot spots in the molecular crystalline explosive 1,3,5-triamino-2,4,6-trinitrobenzene (TATB) for a range of shock strengths and two limiting cases for impact orientation. Isotropic and anisotropic HEq models yield similar results, despite TATB exhibiting some of the largest and most anisotropic thermal conductivity values for explosive near normal conditions. The conductivity is found to be a strong function of density, which parametrically captures dependence on temperature, pressure, and material state. The associated root-mean-square errors of the fitted HEq models are approximately 5% of MD predicted final equilibrium temperatures. Here, the conductivity values determined here for TATB hot spots are considerably larger than those used in a prior hot spot criticality study, which may significantly impact predictions for critical hot spot sizes. The approach provides a convenient foundation for determining the effective thermal conductivity for hot spot problems in other explosives and directly yields information on reasonable approximations that might be taken in higher-level models for those materials.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Performance Evaluation and Costs of a Combined Ground Source Heat Pump and Solar Photovoltaic Storage System in an Extreme Cold Climate

This report outlines the effectiveness and economics of a ground source heat pump system installed together with solar photovoltaic panels and a battery storage system in a local community building situated in a cold climate. The community building is a tribal building located in Ruby, Alaska. Power from solar photovoltaic panels is supplemented by electricity purchased from the local community microgrid. A ground source heat pump was commissioned three years after the building was occupied, and supplements the heat generated by a boiler for both heat and domestic hot water. Data collected over the 2021-2022 heating season shows that the heat pump is providing heat to the building about 19% of the time with an average coefficient of performance of 2.68, ranging from below 2.5 in winter to above 3.0 in summer. The solar photovoltaic panels provided 4,700 kWh of power used within the building and an additional 2,900 kWh exported to the microgrid. The solar-produced power used within the building nearly offsets the estimated annual electrical draw of the heat pump of 5,700 kWh. Due to the very high costs for shipping and installation to remote locations, projects such as this, while not economically feasible if self-funded, can save the community an estimated $76,051 over a period of 20-years. Fuel prices increasing by more than 25%, or subsidized electricity prices decreasing by more than 25%, make the ground source heat pump a more viable option economically. Unsubsidized electricity prices increasing by 25% or more make a solar photovoltaic system with battery storage nearly economically viable after a 20-year period for commercial or school buildings that are not eligible for Alaska's Power Cost Equalization program.

14 SOLAR ENERGY↗

DOE OSTI2022

Understanding the E balance for water management in hydroxide exchange membrane fuel cells

As a key challenge for hydroxide exchange membrane fuel cells (HEMFCs), understanding water management deeply is critical for performance and durability improvement. Here, in this work, we show that the balance between water generation and phase-change-induced (PCI) flow is the main factor controlling cell voltage over a wide range of conditions where the cells are vulnerable to severe flooding. The regulation of flooding by heat generation can be reflected by a stable voltage with increase of current density in the polarization curve. This PCI balance voltage (E balance ), which determines the shape of polarization curve, is modeled as a function of cell operating conditions and gas diffusion layer (GDL) properties. Temperature, pressure, and thermal conductivity of GDL were found important for tuning the level of E balance , both in HEMFCs and proton exchange membrane fuel cells. The understanding of E balance will help to generate strategies for resolving flooding in HEMFCs, and it offers a new perspective for polarization curve interpretation.

25 ENERGY STORAGE↗

DOE OSTI2026

Virtual refrigerant charge sensing algorithm for residential CO₂ heat pumps

Natural refrigerants are increasingly adopted in next-generation heat pump systems, among which CO₂ heat pumps have attracted significant attention. However, due to their high operating pressures, the leakage risk is higher, resulting in undercharge conditions and degraded heat pump performance. Thus, developing an accurate refrigerant charge level detection technique is necessary to guarantee safe and efficient operation. Although virtual refrigerant charge (VRC) level calculation algorithms for CO₂ heat pumps exist, they typically rely on empirically selected features without a systematic selection framework, leading to multicollinearity and potential overfitting, which limit their prediction accuracy and generalizability. To address these issues, this study proposes a VRC algorithm framework with a systematic feature selection method that identifies physically meaningful and statistically significant features, and is applied using a residential CO₂ heat pump as a case study. The method is extended from previous work on conventional refrigerants to account for charge behavior in CO₂ gas coolers. The selected features include gas cooler outlet density, evaporator pressure, and superheat temperature. The results demonstrate that the proposed feature selection method significantly improves prediction accuracy compared to existing VRC approaches. A relatively small training dataset (∼30 samples) is sufficient for feature identification and model development. The developed algorithm achieves less than 3% prediction error under both undercharge and overcharge conditions, representing reductions of 46.7% and 35.3% compared to two recent reference VRC algorithms for transcritical CO₂ heat pumps reported in the literature. The proposed algorithm and feature selection method enhance leakage detection capability, facilitate the deployment of CO₂ heat pump systems, and contribute to reduced energy waste and maintenance costs.

Guo, Fangzhou [Lawrence Berkeley National Laborato↗

DOE OSTI2022

Development of Explainable Data-Driven Turbulence Models with Application to Liquid Fuel Nuclear Reactors

Liquid fuel nuclear reactors offer innovative possibilities in terms of nuclear reactor designs and passive safety systems. Molten Salts Reactors (MSRs) with a fast spectrum are a particular type of these reactors using liquid fuel. MSFRs often involve large open cavities in their core in which the liquid fuel circulates at a high speed to transport the heat generated by the nuclear reactions into the heat exchangers. This high-speed flow yields a turbulent field with large Reynolds numbers in the reactor core. Since the nuclear power, the neutron precursor’s transport and the thermal exchanges are strongly coupled in the MSFR’s core cavity, having accurate turbulent models for the liquid fuel flow is necessary to avoid introducing significant errors in the numerical simulations of these reactors. Nonetheless, high-accuracy simulations of the turbulent flow field in the reactor cavity of these reactors are usually prohibitively expensive in terms of computational resources, especially when performing multiphysics numerical calculations. Therefore, in this work, we propose a novel method using a modified genetic algorithm to optimize the calculation of the Reynolds Shear Stress Tensor (RST) used for turbulence modeling. The proposed optimization methodology is particularly suitable for advanced liquid fuel reactors such as the MSFRs since it allows the development of high-accuracy but still low-computational-cost turbulence models for the liquid fuel. We demonstrate the applicability of this approach by developing high accuracy Reynolds-Averaged Navier–Stokes (RANS) models (averaged flow error less than 5%) for a low and a large aspect ratio in a Backward-Facing Step (BFS) section particularly challenging for RANS models. The newly developed turbulence models better capture the flow field after the boundary layer tipping, over the extent of the recirculation bubble, and near the boundary layer reattachment region in both BFS configurations. The main reason for these improvements is that the developed models better capture the flow field turbulent anisotropy in the bulk region of the BFS. Then, we illustrate the interest in using this turbulence modeling approach for the case of an MSFR by quantifying the impact of the turbulence modeling on the reactor key parameters.

42 ENGINEERING↗

DOE OSTI2024

On the Corrosion Response of Novel Heat Exchangers Manufactured by Casting of Al-Ce-Mg Alloy

Developing low-cost and durable heat exchangers is critical for next-generation heating, ventilation, air conditioning, and refrigeration systems. The emerging requirement to minimize the total refrigerant charge inventory while ensuring a uniform distribution of refrigerant has led to the deployment of advanced manufacturing strategies. At the same time, corrosion is a longstanding issue for metal components, especially those used in heat exchanger (HX) applications. In this study, Al-Ce-Mg alloy-based HXs have been investigated. The corrosion resistance of HXs prototype manufactured by the casting process has been examined and the potential of a new manufacturing approach has been explored to meet the requirements of emerging needs.

Brechtl, Jamieson↗

DOE OSTI2024

Multi-fluid, earth battery energy systems and methods

The present disclosure relates to a system for storing and time shifting at least one of excess electrical power from an electrical power grid, excess electrical power from the power plant itself, or heat from a heat generating source, in the form of pressure and heat, for future use in assisting with a production of electricity. An oxy-combustion furnace is powered by a combustible fuel source, plus excess electricity, during a charge operation to heat a reservoir system containing a quantity of a thermal storage medium. During a discharge operation, a discharge subsystem has a heat exchanger which receives heated CO 2 from the reservoir system and uses this to heat a quantity of high-pressure, supercritical CO 2 (sCO 2 ) to form very-high-temperature, high-pressure sCO 2 at a first output thereof. The very-high-temperature, high-pressure sCO 2 is used to drive a Brayton-cycle turbine, which generates electricity at a first output thereof for transmission to a power grid. The Brayton-cycle turbine also outputs a quantity of sCO 2 which is reduced in temperature and pressure to a heat recuperator subsystem. The heat recuperator subsystem circulates the sCO 2 and re-heats and re-pressurizes the sCO 2 before feeding it back to the heat exchanger to be even further reheated, and then output to the Brayton-cycle turbine as a new quantity of very-high-temperature, high-pressure sCO 2 , to assist in powering the Brayton-cycle turbine.

Buschek, Thomas A.↗

DOE OSTI2024

An Advanced Cooling Device for Concentrated Photovoltaic Systems

Concentrated photovoltaics (CPV) have the potential to significantly enhance the energy conversion utilization of solar panels and reduce solar generation costs, making them a crucial area of advancement in solar power generation technology. However, the concentration of sunlight can lead to overheating of solar panels, resulting in a notable reduction in both the efficiency of solar power generation and the lifespan of the panels. This challenge remains the predominant technical hurdle that hinders the application of concentrated photovoltaic power generation technology. In this study, we propose a new cooling method for concentrated photovoltaic power generation systems via an integrated approach of incorporating Phase-Change Thermal Storage (PCTS) and Thermoelectric Generator (TEG) technology. This new method not only enhances the overall system's electricity generation efficiency but also effectively resolves the technical challenge of concentrated photovoltaic panel overheating issues, ensuring the continuity of concentrated photovoltaic power generation and extending the lifespan of solar panels and their components. In order to make full use of the wasted heat generated by photovoltaic power generation and effectively improve the power generation efficiency of the system, this work developed a phase change heat storage device based on a phase change material. This device uses the temperature difference between day and night to recover wasted heat from photovoltaic power generation. Through integration with the thermoelectric power generation system, thermal energy can be converted into electrical energy. In addition, the Peltier effect of thermoelectric materials is used to construct a photovoltaic panel overheating protection system, which significantly improves the reliability and service life of the system.

14 SOLAR ENERGY↗

DOE OSTI2023

Togiak Heat Recovery Project

Togiak is one of hundreds of Alaskan Native, roadless communities only accessible by boat or plane. This project constructed a heat recovery (HR) system which pipes what was previously wasted heat generated at the power plant to four nearby community buildings. The power plant houses diesel fired generators which provide electricity to the community. This project designed and constructed the system that recovers a portion of the heat produced by the generators and pipes it to the end-user buildings. The heat recovery system integrates with each building’s internal heating system. The objective is to significantly reduce the heating costs in these four community facilities. By reducing the energy use and cost in these community facilities, the local economy is strengthened by keeping the funds inside the community that were formerly used to purchase imported fuel, thereby multiplying the impact of the energy cost reduction. Energy independence is enhanced and energy resilience is increased by reducing dependence on long fuel supply chains which are easily interrupted by unpredictable natural and man-made disasters such as earthquakes, climate change, road rail and sea accidents, etc.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

An Advanced Cooling Device for Concentrated Photovoltaic Systems

Gou, Yimeng↗

DOE OSTI2022

Large-scale reactive thermoset printing: Complex interactions between temperature evolution, viscosity, and cure shrinkage

Thermoset composites are strong candidates for large-scale material extrusion additive manufacturing (AM). However, uncured thermoset composites become unstable as print height increases. Here, chemical initiation of vinyl ester immediately before deposition was used to suppress collapse and enable large-scale thermoset printing. Structural stability was assessed by printing thin walls at various layer times and monitoring thermal gradients with an infrared camera. Stable printing was observed at a layer time of 4.50 min, approximately half the gel time of the material (8 min). Self-weight collapse occurred at short layer time (0.68 min), whereas warpage occurred at long layer time (6.50 min). Here, a new behavior was discovered at intermediate layer time (2.25 min) where the heat generated by the reaction causes new, un-gelled layers to flow. Forced convection eliminates this behavior, stabilizing the 2.25-min layer time print. These findings motivated development of a less exothermic material system, which was used to print a large-scale mold and demonstrate the value of this understanding. By presenting these challenges of large-scale reactive thermoset AM for the first time, this work motivates focused studies of the complex interplay between rheological, thermal, and chemical behaviors to improve the feasibility of large-scale thermoset AM. Tensile properties of the printed material were also measured. Longitudinal and transverse elastic moduli are 3.79 and 2.95 GPa, respectively, and corresponding tensile strengths are 36.11 and 18.83 MPa. The glass transition temperature is 93.13 °C.

36 MATERIALS SCIENCE↗

DOE OSTI2026

Beyond interpolation: Physics-inspired gating transformers for extrapolating irradiation conditions to novel nuclear fuels

The qualification of advanced nuclear fuels relies on irradiation experiments in test reactors that emulate commercial conditions. Designing these tests requires accurate prediction of key irradiation quantities, particularly heat generation rate and burnup, yet obtaining them typically involves computationally expensive multi-step simulation workflows. We propose a physics-inspired gating transformer (PIGT) that integrates an inverse-square, distance-based attenuation into the encoder representation to bias attention toward physically relevant spatial relationships while retaining data-driven flexibility. Using MiniFuel irradiation data from the High Flux Isotope Reactor at Oak Ridge National Laboratory, we benchmark against ensemble methods, feedforward and recurrent networks, convolutional models, and standard transformers. While baseline models perform well under interpolation, they exhibit a pronounced generalization gap when evaluated on fuels not included in the training set. The proposed model consistently improves extrapolative accuracy and stability, yielding the strongest performance on unseen fuel configurations. These results indicate that a lightweight physics structure embedded within attention mechanisms can substantially improve robustness, enabling more reliable surrogate predictions to accelerate the design of nuclear fuel irradiation experiments.

Fuel qualification↗

DOE OSTI2025

Total Recycling of Copper Cable Scrap and Production of Carbon Using Fast Microwave Technology

The recycling of cable scrap, particularly from discarded electrical wiring, is gaining significant attention due to the rising demand for copper and the need for sustainable management of electronic waste. Traditionally, mechanical and thermal processings have been used to recover copper and plastic from cables. However, these approaches are often energy-intensive, time-consuming, and costly in terms of equipment and labor. In this study, we present a simple and effective method for recovering materials from cable scrap using a domestic microwave oven. Cable pieces (2–2.5 cm long) were exposed to 700 W of microwave irradiation under rotation for 30 s, enabling the rapid and efficient separation of high-quality copper metal from the core wire, and activated carbon from the carbonized plastic sheath. Microwaves facilitate this process through Ohmic heating, which induces electrical resistance in the metal, generating heat that mechanically loosens the metal and carbonized plastic components. The process demonstrates high efficiency, achieving an 80% reduction in energy consumption compared to conventional processings. This fast and energy-efficient method shows strong potential for scaling up to industrial recycling, offering a cost-effective and environmentally friendly way to recover high-quality materials for further use or repurposing.

Bourlinos, Athanasios B. (ORCID:0000000256165993)↗

DOE OSTI2024

Decarbonization Technology Snapshot: Heat Pump Water Heaters

Heat pump water heaters use electricity to move heat from one place to another instead of generating heat directly. In many cases they replace gas-fired water heaters and are significantly more energy efficient, reducing on-site Scope 1 emissions and often resulting in reduced total emissions.

building decarbonization↗

DOE OSTI2025

Shadow masks predictions in SPARC tokamak plasma-facing components using HEAT code and machine learning methods

Here, this work uses machine learning (ML) to complement HEAT (Heat flux Engineering Analysis Toolkit) by developing 3-D footprint surrogate models for fast and accurate heat load calculations in the divertor of the SPARC tokamak. The focus is on shadowed regions, or magnetic shadows, caused by the 3-D geometry of plasma-facing components (PFCs). ML classifiers are employed to create a surrogate model for HEAT generated shadow masks, predicting these shadow masks and divertor heat flux profiles based on a diverse range of equilibria and only the plasma current, safety factor(q95) at the edge, and magnetic flux angles as input parameters. The ultimate goal is to integrate the model for real-time control and future operational decisions.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗