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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 OSTI2025

Glass Furnace Decarbonization Technology Stack (Final Technical Report)

This report summarizes the objectives, approach, and outcomes of the Glass Furnace Decarbonization Technology Stack project undertaken by Owens-Brockway Glass Container Incorporated under award number DE-CD0000093. The project aimed to implement a pioneering combination of furnace technologies at the Zanesville, OH manufacturing site to reduce carbon intensity (CI) by 20–40% compared to baseline operations. The proposed Furnace Technology Stack included a Gas/Oxy-fuel system, OPTIMELT™ Heat Recovery System, raw material pre-heating, electric boosting, and forehearth electrification—designed to demonstrate commercial feasibility and drive industry-wide decarbonization.

42 ENGINEERING↗
DOE OSTI2024

Enhanced Bottom Anode Monitoring in DC Electric Arc Furnaces Using Fiber-Optic Sensors

A pin style bottom anode employs conductive steel rods that serve as the pathway for the high electrical power through rammed refractory at the bottom of a DC Electric Arc Furnace (EAF). Anode wear during operation is important to monitor, as anode replacement is expensive and impacts EAF productivity. Liquid steel penetration into the un-sintered refractory layer can result from rapid electrical power ramp-up, dips in furnace temperature, or operating the anode for too long between EAF campaigns. In extreme cases, the liquid steel may penetrate the bottom of the furnace when anode wear progresses too close to the bottom shell, which is extremely dangerous and must be avoided. The current state of the art for monitoring bottom anode wear employs thermocouples imbedded in the anode pins at points in the anode. However, this approach is not sensitive enough to detect localized damage to the anode, especially when cracking occurs. Here, the present work utilizes fiber optic sensors to monitor the health of the anode, by creating a real-time spatially distributed temperature map of the anode. Unlike the traditional thermocouples, these sensors can be mounted at significantly greater depths, provide distributed temperature measurements, and can withstand temperatures of up to 900°C. Additionally, they are able to perform temperature measurements with a spatial resolution of 1.3 mm at a 5 Hz acquisition rate, providing unprecedented high-density real time monitoring of anode health and increasing the efficiency, and safety of EAF operation.

Bottom Anode↗
DOE OSTI2023

Machine Learning-Based Regression Models for Ironmaking Blast Furnace Automation

Computational fluid dynamics (CFD)-based simulation has been the traditional way to model complex industrial systems and processes. One very large and complex industrial system that has benefited from CFD-based simulations is the steel blast furnace system. The problem with the CFD-based simulation approach is that it tends to be very slow for generating data. The CFD-only approach may not be fast enough for use in real-time decisionmaking. To address this issue, in this work, the authors propose the use of machine learning techniques to train and test models based on data generated via CFD simulation. Regression models based on neural networks are compared with tree-boosting models. In particular, several areas (tuyere, raceway, and shaft) of the blast furnace are modeled using these approaches. The results of the model training and testing are presented and discussed. The obtained R 2 metrics are, in general, very high. The results appear promising and may help to improve the efficiency of operator and process engineer decisionmaking when running a blast furnace.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2022

Modeling and Analysis of a Thermophotovoltaic Integrated Self-Powered Furnace

This work investigates the energy efficiency and carbon reduction potential of self-powered residential building heating equipment using a thermodynamic modeling approach. An integrated thermophotovoltaic power module and residential scale furnace system (40,000 Btu/h) were modeled and studied in detail to assess the influence of different design configurations on primary energy efficiency. Operational characteristics such as total power generation, electrical efficiency, and heat recovery were examined in a self-powered system configuration. A sensitivity analysis was conducted to determine the influence of the electric grid’s carbon dioxide footprint (carbon intensity) and the cost of electricity on the environmental, as well as the economic, benefit associated with the self-powered configuration. Compared with a traditional furnace powered by an electric grid at a carbon intensity of 0.5 kg CO 2eq /kWh EL , the self-powered furnace was shown to decrease the annual carbon dioxide emissions by approximately 550 kg (~75% reduction), while also saving more than USD 200 in utility expenses, annually. Additionally, the carbon emission reduction potential of blending different concentrations of hydrogen in natural gas fuel was also studied.

14 SOLAR ENERGY↗
DOE OSTI2023

Effect of bimetallic modification on blast furnace slag and its application in low‐temperature selective catalytic reduction

Abstract Objective In order to control NO x in low‐temperature flue gases emitted from non‐power industries and to reduce the preparation cost of denitration catalysts, this study uses inexpensive blast furnace slag as raw material to prepare denitration catalysts. Methods After cooling, drying and grinding, the blast furnace slag becomes a powder with considerable fineness and meets the requirements of activity index, which is called GGBS (ground granulated blast furnace slag). Using GGBS as denitration catalyst carrier, the active components M (M = Fe, Co, Ni, Cu and Ce) are loaded on Mn‐based GGBS catalyst using an impregnation method. Conclusions The effect of different active components on the denitration performance and sulfur resistance of Mn‐based GGBS catalysts is investigated. The results show that the Mn‐Ce/GGBS catalyst has better denitration performance and sulfur resistance. The Mn‐Ce/GGBS catalyst has a significant denitration performance when load ratio is 2:1. The active component Ce improves the denitration performance of the catalyst, reduces sulfur poisoning and extends the life of the catalyst. The SO 2 in the flue gas increases the acid sites on the catalyst surface and improves catalyst activity. The larger the ratios of Mn 4+ /Mn 3+ , Ce 4+ /Ce 3+ and O α /O β , the stronger the catalyst activity and the better the denitration performance. © 2022 Society of Chemical Industry (SCI).

Zhang, Lei↗
DOE OSTI2020

Design and performance of high-temperature furnace and cell holder for in situ spectroscopic, electrochemical, and radiolytic investigations of molten salts

To facilitate the development of molten salt reactor technologies, a fundamental understanding of the physical and chemical properties of molten salts under the combined conditions of high temperature and intense radiation fields is necessary. Optical spectroscopic (UV–Vis–near IR) and electrochemical techniques are powerful analytical tools to probe molecular structure, speciation, thermodynamics, and kinetics of solution dynamics. In this paper, we report the design and fabrication of three custom-made apparatus: (i) a multi-port spectroelectrochemical furnace equipped with optical spectroscopic and electrochemical instrumentation, (ii) a high-temperature cell holder for time-resolved optical detection of radiolytic transients in molten salts, and (iii) a miniaturized spectroscopy furnace for the investigation of steady-state electron beam effects on molten salt speciation and composition by optical spectroscopy. Initial results obtained with the spectroelectrochemical furnace (i) and high-temperature cell holder (ii) are reported.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2024

Development of Clean Condensing Furnace Using Advanced Catalyst

A clean condensing furnace was developed by using acidic gas reduction (AGR) catalysts. The AGR catalyst technology is capable of minimizing condensate acidity and NOx emissions in advanced gas furnace. In the study, different AGR catalyst materials were explored. The AGR with low Pt/Rh loading achieves an improved annual fuel utilization efficiency (AFUE) without impairing the performance in achieving neutral condensate and ultralow NOx emissions. The AGR with low Pt/Rh loading enables even better ability to convert NOx. Moreover, the low-cost AGR realizes nearly zero cold-start CO emissions, as is attractive in the battle to keep public safe from dangerous CO in furnaces.

Gao, Zhiming↗
DOE OSTI2021

Out-of-Pile Furnace Tests on Fast Reactor Metallic Fuels Conducted at the AGHCF

An extensive out-of-pile furnace test program was conducted at Argonne’s Alpha-Gamma Hot Cell Facility (AGHCF) from 1987-1994 to evaluate the fuel/clad compatibility and performance of fast reactor metallic fuels. This test program included over 150 tests on irradiated fuels conducted in two furnace apparatuses. The available records of these tests have been preserved with the support of the Advanced Reactor Technology program and organized in the OPTD (Out-of-Pile Transient Database). This report provides at-a-glance summary information for each of the out-of-pile furnace tests, including information about the tested fuel samples, test conditions, purpose of the tests, and key results. It is intended for open and unlimited distribution to allow all interested persons to view key information about the out-of-pile tests.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

High-Accuracy Simulations to Model Pyrometallurgical Processes in a Secondary Lead Reverberatory Furnace

The US manufacturing industry produces about 1.3 million tons of refined lead each year using secondary sources consisting mainly of lead batteries. ORNL is partnering with Gopher resource, the second largest lead recycling company in the United States, and GTI, to develop a high-fidelity CFD model of a directly fired, reverberatory-style, secondary lead furnace. These High Performance Computing (HPC) simulations are aimed to use first principles modeling for combustion and melting processes of the secondary lead feed while accounting for complex interphase interactions between the gas, solid charge (lead) material, slag, and metal phases. Through validation against operating plant data, this effort will enable significant improvements in design, operational parameters, and energy efficiency, thus improving productivity and refractory lifetime of secondary lead melting furnaces. Estimated savings/reduction of, at least, 1 trillion BTU, 1 million ton/year of greenhouse gas emissions, and $\$50$ million/year to the US lead industry can be expected. ORNL resources and expertise in high-performance computing and multicomponent, multiphase flows were utilized to realize this goal while advancing the understanding of the smelting and melting processes occurring within the furnace.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS1974

Furnace systems development

Space processing facilities, including furnace systems, will, only vaguely resemble their laboratory and industry counterparts. Within the constraints imposed by the host vehicle, flight furnaces will be more versatile. They will provide a wider range of controlled heating, cooling and sample positioning to accommodate the requirements of experiment scientists, and will be more efficiently packaged. The development of these advanced furnace systems will be an essential element in the orderly evolution of space processing technology.

Aldrich, B. R.↗
NASA NTRS1974

2200 C oxidizing atmosphere furnace for space manufacturing

The design of a high temperature furnace is presented which uses electrically conducting ceramic oxide heating elements. The heating elements are made of either thoria or stabilized zirconia which become conductive when preheated to 700 to 1000 C. These heater elements can be operated to 2200 C in oxidizing or inert atmospheres. The furnace is being designed to have a temperature which can be controlled to within 11 C. By a replacement of the heater element, the working cavity can be changed from isothermal to a cavity with a selected specific axial temperature gradient of up to 200 C per centimeter. This furnace concept is appropriate for the growth of crystals which might be grown best in an oxidizing atmosphere such as sapphire (melting point 2040 C), yttrium aluminum garnet (1970 C) or yttrium orthoaluminate (1875 C).

Halbach, C. R.↗
NASA NTRS1978

Narrow zone heating by a new radiation focusing technique - Toroidal ellipsoid furnace

The paper describes the design of a toroidal ellipsoid furnace for narrow zone heating of materials in sealed transparent ampoules. The heater is a toroid flattened to an elliptical cross section like a partially inflated inner tube resting on a horizontal surface. The foci of the ellipsoid are two concentric rings. The outer focus is occupied by a heater wire, and the inner focus is arranged to fall on the surface of the cylindrical ingot within its transparent capsule. One advantage of the new furnace is that the wire heater closely approximates the ideal shape, lying along an extended line focus, as opposed to the elusive point source of the Costello furnace. Also, the ingot is heated uniformly around its circumference.

Davidson, M. C.↗
NASA NTRS1979

General purpose rocket furnace

A multipurpose furnace for space vehicles used for material processing experiments in an outer space environment is described. The furnace contains three separate cavities designed to process samples of the widest possible range of materials and thermal requirements. Each cavity contains three heating elements capable of independent function under the direction of an automatic and programmable control system. A heat removable mechanism is also provided for each cavity which operates in conjunction with the control system for establishing an isothermally heated cavity or a wide range of thermal gradients and cool down rates. A monitoring system compatible with the rocket telemetry provides furnace performance and sample growth rate data throughout the processing cycle.

Aldrich, B. R.↗
NASA NTRS1985

Temperature-Gradient Furnace for Solidification Experiments

Gradients are controllable from zero to 500 degrees C/cm. Typical temperature profile superimposed on partial cross section of furnace. Steepness of gradient varied by adjusting flow of energy to and from different zones of furnace. Specimen placed in ampoule moved inside ceramic tube according to needs of experiment. Furnace provides axial temperature profiles for material processing experiments.

Aldrich, B. R.↗
NASA NTRS1986

Research Furnace for Crystal Preparation

Three-zone furnace tested and characterized for preparation of lead-tintelluride (LTT) crystals. Tests show temperature in furnace controlled to obtain constant rate of movement of high-temperature isotherm down length of furnace. Temperature profiles accurately controlled by three independent heaters. Control software brings separate heaters to any desired temperature.

Crouch, R. K.↗
NASA NTRS1986

Furnace for Tensile Testing of Flexible Ceramics

Ceramic cloth and thread tested quickly at temperatures up to 1,250 degree C. Tensile strengths of ceramic cloths and threads measured conveniently in new furnace at specified temperatures up to 1,250 degree C, using ordinary mechanical tester. Samples heated along part of their lengths in furnace slots. Interchangeable furnace chambers and matching heating elements sized to match size of tested ceramic material.

Smith, M.↗
NASA NTRS1984

Solidification behavior of low and high thermal conductivity materials in a Bridgman-Stockbarger furnace

The solid-liquid interface position and the temperature gradients in both the solid and liquid at the interface have been studied in a modified Bridgman-Stockbarger crystal growth furnace. These crystal growth factors have been studied as a function of ampoule translation rate, materials properties, and the size and temperature of a small auxiliary heater placed at the edge of the furnace hot zone. It has been found that the interface position with respect to a furnace reference point is essentially constant during a run for a low thermal conductivity material whereas the interface position changes continuously during a run with high thermal conductivity material. However, the ampoule translation rate and auxiliary heater conditions produce interface position changes in both high and low thermal conductivity materials.

Ejim, T. I.↗
NASA NTRS1989

Improved Transparent Furnace For Crystal-Growth Experiments

Novel design and fabrication process for transparent crystal-growing furnace developed. Design consists of one or more heater zones in which heating wire coiled around insides of quartz tubes. Ampoule of material supported inside furnace by guide wire. Crystal then grown by directional freezing of material in ampoule. Distinct feature of use of quartz is capability of direct visual observation of crystal-growth process during experiment. Study of transparent electronic materials conducted in new furnaces.

Rosenthal, Bruce N.↗