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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 901 records · Page 50
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Experimental study of mechanistic factors influencing solvent-driven fractional crystallization of calcium sulfate

To advance dimethyl ether-driven fractional crystallization (DME-FC), a more sustainable method of water treatment and mineral recovery, a range of chemical equilibria were measured. These include varying concentrations of miscible organic solvents (MOS) used to experimentally measure the solvent-induced solid-liquid equilibrium (SLE) of calcium sulfate (CaSO 4 ) in water. Seven MOS, including dimethyl ether (DME), acetonitrile (MeCN), 1,4-dioxane, tetrahydrofuran (THF), acetone, ethanol, and diethylamine, were screened to establish trends associated with molecular volume, functional groups, and physical properties. The effect of MOS on CaSO 4 removal differed at concentrations <0.15 mol fraction MOS; MOS with greater molecular volume (THF, 1,4-dioxane, and diethylamine) induced greater CaSO 4 precipitation on a per mole basis. The solvent-induced SLE for all MOS converged between 0.15 and 0.2 mol fraction MOS, reaching a CaSO 4 concentration consistent with a water to MOS hydration ratio of 5:1 to 6:1, which may correspond to the solvent generating a solution-based pseudo-clathrate structure with continuity within the solution. Finally, solution pseudo-clathrate structures provide a mechanistic basis for DME-FC.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Hydrothermal liquefaction of wastewater-grown algae to produce synthetic aviation fuel: A combined experimental study and techno-economic assessment

Large-scale algae farms may someday become a consistent source of biomass feedstock for biofuels. Near-term supplies of algal biomass are available at certain water resource recovery facilities as algae cultivation is used as a method for nutrient recovery from specific effluent streams. Algae grown as a service shifts the value to the service rather than its sole use as a feedstock, which could enable the provision of algal biomass at low to no cost to biofuel producers. Hydrothermal liquefaction (HTL) can readily upgrade wet feedstock slurries, such as algae, to produce a carbon-enriched biocrude. The HTL biocrude can be hydrotreated and distilled, producing a variety of distillate fuels, including synthetic aviation fuel (SAF). We present a pathway, showing the experimental production of SAF from wastewater-grown algae via HTL, along with a techno-economic assessment to identify opportunities for process improvements. Critical quality attributes of the SAF, such as density, viscosity, surface tension, and freeze point, were estimated within the expected fuel experience ranges when compared against petroleum jet fuel. The average minimum fuel selling price of fuels from wastewater-grown algae for breakeven economics was $\$9.04$ per gasoline gallon equivalent (GGE). The sale of co-products such as struvite fertilizers and cement additives can add revenue to reduce the net cost. Ultimately, the selling price is influenced by the scale of the HTL processing facility. Adjusting estimations in the process scale, algae yield, and capital cost estimation can lower the price to $\$6.51$/GGE or raise it to $13.07/GGE.

Biofuels↗
DOE OSTI2020

Experimental validation of solid oxide fuel cell polarization modeling: An LSM-YSZ/YSZ/Ni-YSZ case study

Polarization modeling based on the measured I-V curves is a useful tool for analyzing SOFC performance and diagnosing performance limitations. Using the polarization model, the overpotential of a cell is usually separated into different polarization contributions, including area specific ohmic polarization, activation polarization, and anodic and cathodic concentration polarizations. In this study, we aim to experimentally validate the accuracy of the polarization model. As a case study, anode-supported cells with LSM-YSZ/YSZ/Ni-YSZ configuration are used. By curve-fitting the I-V curves of a cell tested under different cathode oxygen partial pressures into the polarization model, the contributions of different polarization losses are quantified. To validate the polarization model, independent experiments/studies including electrochemical impedance spectroscopy, cathode kinetics study, ex-situ diffusivity measurement, and tortuosity measurement using 3D reconstructed anode are conducted. The results from polarization modeling and from validation studies are in good agreement, thereby validating the polarization model for SOFC performance analysis.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Tuning and high throughput experimental screening of eutectic electrolytes with co-solvents for redox flow batteries

Eutectic solvents, with high salt concentrations and suppressed volatility, are promising alternatives to aqueous and volatile organic electrolytes for grid-scale energy storage devices such as redox flow batteries (RFBs). However, it is not known a priori which hydrogen bond acceptors and donors would form a eutectic solvent and at which compositions of these mixtures would yield desirable properties for RFBs. Specifically, the known deep eutectic solvents generally have high viscosities and low ionic conductivities, especially in the landscape of RFB electrolytes. We report a high throughput experimental (HTE) study was carried out to assess the properties of eutectic solvents based on choline chloride as the hydrogen bond acceptor and ethylene glycol and aniline as the hydrogen bond donors. In addition, water, acetonitrile, and dimethyl sulfoxide as co-solvents were examined in terms of tuning the viscosity, conductivity, and solubility of two redox-active species: methyl viologen dichloride hydrate (MVCl 2 ·H 2 O, or MV for simplicity) and 2,1,3-benzothiadiazole (BTZ) that are relevant to RFBs. The HTE framework enabled the development of a rapid and comprehensive understanding of the design of new eutectic electrolytes incorporating co-solvents to improve the physicochemical and electrochemical properties for RFBs.

25 ENERGY STORAGE↗
DOE OSTI2025

Experimental characterization and potential energy savings of insulated cladding for U.S. residential buildings

This study evaluates a novel insulated cladding composed of foamed cement and vinyl siding that is designed as a retrofit product to enhance thermal performance in U.S. residential buildings. Experimental measurements showed that foamed cement exhibits a thermal conductivity of 0.0334–0.0365 W/m-K (R-value of 4.0–4.3 °F⋅ft 2 ⋅h/BTU), which is significantly higher than that of conventional fiber cement boards. Although mechanical testing confirmed the material’s brittleness and low strength, it also indicated its suitability for nonstructural insulation applications. Water vapor permeability testing demonstrated effective moisture resistance with the polymer coating. To evaluate the insulated cladding’s energy performance, we used the U.S. Department of Energy’s prototype single-family building model and simulated across 50 locations spanning 16 International Energy Conservation Code climate zones. The R-7 (R-value of 7 °F⋅ft 2 ⋅h/BTU per inch) retrofit cladding resulted in heating energy savings up to 275 therms (Fairbanks, AK) and cooling energy savings up to 1,547 kWh (Phoenix, AZ). The energy cost savings varied by region, but the highest annual cost savings ($\$$434/year) were observed in Santa Maria, CA, and the highest annual cost savings percentage (37 %) were noted in Monterey, CA. On a national scale, the insulated retrofit provided an average annual energy cost reduction of 16 %, highlighting the cladding system’s broad applicability and financial viability.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2026

Machine learning-enhanced MPC for demand flexibility in small commercial buildings: An experimental study

Small- and medium-sized commercial buildings (SMCBs) represent the majority of U.S. commercial building stock and a significant share of peak electricity demand, yet they often lack centralized building automation systems, representing a significant untapped resource for urban energy management. This infrastructure gap makes advanced control implementation challenging, limiting the potential for widespread demand flexibility. Model Predictive Control (MPC) has shown strong potential for load shifting, peak demand reduction, and cost savings, but its effectiveness is hindered by unmeasured disturbances such as internal heat gains. This paper presents a Hybrid MPC framework that integrates a physics-based gray-box building thermal model, identified using a lumped disturbance (LD) approach, with a machine learning (ML) model for forecasting unmeasured disturbances. The hybrid approach is designed for buildings with multiple individually controlled heat pump and thermostat pairs, common in SMCBs, and aims to optimize coordinated scheduling of multiple heat pumps under dynamic electricity pricing while respecting comfort constraints. The methodology is validated through both simulations of case study buildings and experimental studies at a highly-instrumented test facility. Simulation results show that the Hybrid MPC achieves substantial load shifting and peak demand reduction, approaching the performance of an ideal MPC with perfect disturbance knowledge, and outperforming a conventional MPC without disturbance forecasting. In experiments, the Hybrid MPC reduced daily HVAC energy costs by 8.7%, peak-price time load (load shifting) by 41.7%, and peak demand by 29.2% compared to baseline control, demonstrating comparable benefits to the 11.6% cost savings, 42.9% load shifting, and 23.2% peak reduction of the ideal MPC. These results demonstrate that the proposed hybrid modeling approach can significantly improve MPC performance in real-world SMCB applications without requiring additional disturbance measurements.

Demand Flexibility↗
DOE OSTI2023

Experimental performance of ejector heat pump operating in the sub-critical mode

Ejector heat pump (EHP) is an efficient-energy technology with a promising potential to replace the vapor compression cycle in heating and cooling applications. It can be powered by low-grade waste heat and uses environmentally friendly working fluids. EHP has also become a viable solution in research seeking cooling applications. However, little attention has been paid to using EHP for heating purposes. In order to investigate this, a steam EHP for domestic water heating was designed and built. The coefficient of performance (COP) is evaluated at various operating and design conditions in sub-critical operational modes to achieve higher condensation temperatures. Two primary nozzles with a throat diameter of 1.5 mm and 2.0 mm were investigated. The primary nozzle is movable along the ejector’s axis, allowing investigation of its positional effects on the EHP’s COP. Further, experimental measurements revealed that using a smaller throat diameter results in a high COP and low back pressure. The EHP COP and back pressure increase when the LTE temperature increases. Using a throat diameter of 1.5 mm, the EHP COP increases as the nozzle exit position (NXP) becomes closer to the constant area section. A COP of 2.42 and a back pressure of 4.28 kPa are achieved at a high-temperature evaporator (HTE) temperature of 130 °C and a low-temperature evaporator (LTE) temperature of 30 °C using a primary nozzle with 1.5 mm.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2026

Experimental characterization and analysis of phase change material-based thermal energy storage system for refrigerated display case

Refrigerated display cases that are used to store and exhibit food products in supermarkets and retail spaces consume a significant portion of the buildings’ total electricity. Importantly, the refrigeration-related energy cost and demand charges are greatly affected by the time-of-use electricity pricing and demand rates, which are at their maximum during peak hours, typically when refrigeration energy consumption is also high. Using energy storage to shift the refrigeration load from peak to off-peak hours can greatly reduce the operational costs in the supermarket. This study demonstrates a phase change material-based thermal energy storage (TES) system, specifically designed in stackable units, that can be integrated with an open vertical refrigerated display case. We perform numerical and experimental characterization that includes finite-difference modeling for the TES, prototype fabrication, and laboratory evaluation, followed by a preliminary system-level analysis to predict the impact of TES on the refrigerated case performance, energy use, and energy cost. The results show that the dedicated latent TES for refrigerated cases can provide a specific energy of 50.4 Wh/kg and a specific power of 15.5 W/kg. The TES can be charged during 12 h of the off-peak period and discharged at various rates during 4 to 6 h of the peak period, thereby shifting the refrigeration load from the peak to the off-peak period. Consequently, annual cost savings up to 19% can be achieved, depending on the thermal load, the summer/winter peak electricity pricing, and the transition temperature of the phase change material used.

25 ENERGY STORAGE↗
DOE OSTI2026

Comparative assessment of new oxygen carrier materials for gas switching reforming of natural gas: Techno-economics assessment, life cycle analysis, and experimental insights

The increasing demand for hydrogen and the CO 2 intensity of natural gas (NG) reforming motivate the development of low-carbon-emission hydrogen production technologies. Gas Switching Reforming (GSR) with integrated CO 2 capture, a technology based on Chemical Looping Reforming (CLR), has been experimentally proven and shows potential for scale-up. In this study, select oxygen carriers (OC) (NiO/Al 2 O 3 , Fe 2 O 3 -CeO 2 /Al 2 O 3 , and magnetite) were tested in methane steam reforming in a fixed bed reactor to determine their relative reactivities under relevant conditions for GSR (800 °C, 7 bar total pressure). Process models were then developed to perform techno-economic analysis (TEA) of GSR for hydrogen production (GSR-H 2 ) and a combined cycle (GSR-CC) in which high-purity H 2 is fired in a gas turbine to produce electricity. Operating at 10 bar and 1100 °C and with the additional recovery steps implemented increased H 2 production by ∼ 30% and improved efficiency relative to prior studies. For GSR-H 2 , the levelized cost of hydrogen (LCOH) is 1.61–1.64 $/kg-H 2 , competitive with a reference SMR case, though operating and maintenance costs are higher due to increased electricity demand. GSR-CC has a significantly higher levelized cost of electricity (LCOE) than its reference NGCC (natural gas combined cycle) plant, suggesting it is less competitive; however, increasing production scale could make it more attractive. Life-cycle results for GSR-H 2 indicate NG consumption drives ∼ 75% of total global warming impacts (∼2.3 kg CO 2 eq/kg H 2 ). An environmental, health, and safety screening suggests iron-based carriers are comparatively safer, whereas NiO may pose greater risks. Overall, GSR-H 2 is a scalable, competitive option for hydrogen production using nickel and non-nickel OC.

03 NATURAL GAS↗
DOE OSTI2023

Experimental flow-through a single fracture with monolayer proppant at reservoir conditions: A case study on Caney Shale, Southwest Oklahoma, USA

Global energy systems are undergoing a crucial transition to clean energy sources, thereby moving away from fossil-fuel based energy with the ultimate aim of reducing carbon dioxide emissions. It is essential to continue to advance in exploring and developing shale gas resources as this will underpin the global supply of natural gas that is needed to support the energy transition. The challenge hereby is that the slow fluid flow of the shale matrix due to its very low permeability requires large-scale volume fracturing to produce a conductive fracture network that enhances the connectivity between the shale formation and the wellbore. This work examines the influence of a thin proppant layer on a single fracture using a flow-through experiment, and also explores whether proppant embedment in the Caney shale is affected by the rock mineralogy, surface roughness, fluids, confining stress, time, temperature and bedding. The experiment was conducted for a duration of nine days (216 h), experimental temperature was varied from ambient temperature to reservoir temperature of 125 °C (257 °F) and confining stress was varied from 367 psi (2.53MPa) to a maximum of 4011.82 psi (27.66 MPa). Here, we find that the conductivity of the fracture is primarily influenced by the layer of proppant used, surface roughness, mineralogy, fluids, temperature and closure stress.

Caney shale↗
DOE OSTI2025

Experimental data for damage mechanics simulation challenge

While there are many computational approaches for simulating damage in rock and other materials, few have been ground truth tested with either known experimental data or with blind data sets. Here, in this work, we present a bench-mark laboratory data set for a damage mechanics challenge to compare computational approaches on damage evolution in brittle-ductile materials. The samples were fabricated through additive manufacturing to produce repeatable specimens designed to fail in controlled ways. The failure was induced in the samples using a 3-point bending test to produce different Modes such as Mode I and mixed Modes including I-II, I-III and I-II-III Modes to generate a calibration data set and a blind challenge data set. Data collected included spatial and temporal measurements from traditional digital load–displacement sensors, 2D digital image correlation measurement to map surface deformations, 3D X-ray microscopy to ground-truth the crack-failure geometry, and laser profilometry to capture surface roughness. The data sets are available, on a data repository, to the community to advance computational models to improve our ability to predict damage in brittle-ductile materials.

3-point bending↗
DOE OSTI2025

An experimental study on gas-liquid phase fluid migration in hydrate-bearing sediments during hydrate dissociation

Natural gas hydrate production tests face problems such as severe sand blockage, poor gas-liquid phase separation, and significant land subsidence. This is because of the insufficient understanding of the complex phase transition and gas-liquid multi-phase fluid migration during hydrate dissociation. In hydrate-bearing sediment systems, hydrate phase transition couples with gas-liquid fluid migration. The phase transition causes changes in pore structure, which in turn modifies porous infiltration parameters and fluid flow capacity. Meanwhile, alterations in phase interfaces affect key parameters like surface tension and wettability. Gas-liquid fluid migration influences heat and mass transfer, thus affecting phase equilibrium and dissociation rates. To bridge the gap in describing gas-liquid fluid migration during hydrate dissociation in experiments, this research innovatively integrated an unsteady-state gas displacement by water and a quantitative hydrate dissociation process, independently developed a multi-phase seepage experimental system suitable for hydrate dissociation and determined the relationship between seepage parameters and hydrate saturation under different porosity. The results are as follows: a) Core samples with higher initial porosity show a greater recovery rate of fluid flow capacity. b) The retarding effect of multi-phase fluid has a more significant impact on the migration of the wetting phase fluid (water) than that of the non-wetting phase fluid (methane). c) During hydrate dissociation, the evolution of absolute permeability shows an “S-shaped” pattern, and the evolution of relative permeability shows a “wiring-harness” pattern. In conclusion, the findings can provide a theoretical basis for preventing geological disasters and for geotechnical engineering design during hydrate production.

58 GEOSCIENCES↗
DOE OSTI2025

Cross-scale modeling and experimental integration for advancing cathode electrolyte interphase studies in high energy density lithium-ion batteries

Electrochemical interfaces are critical to the performance and durability of lithium-ion batteries (LIBs). The solid electrode-electrolyte interphase (SEI and CEI) structures that form during cycling can passivate reactive surfaces, ensuring safe operation, but also may contribute to performance degradation. Understanding the microscopic factors influencing interphase formation, growth, and evolution is essential for balanced battery design. While significant research has focused on the anode-electrolyte interphase (SEI), the cathode-electrolyte interphase (CEI) remains less explored, despite its importance in high-voltage and advanced battery technologies. Challenges in conducting in-situ or operando experiments arise from the occluded nature of these interfaces and the long timescales involved, often leading to biased interpretations. A validated multi-scale, multi-physics modeling approach, integrated with advanced characterization techniques, can effectively elucidate the intrinsic stability of electrolyte and cathode surfaces, the impact of chemical heterogeneity, and the role of microstructural features on CEI performance. In conclusion, this article reviews current modeling and simulation strategies for studying CEI in advanced LIBs and highlights opportunities for future methodological advancements and experimental integration.

Cathode-electrolyte interphase↗
DOE OSTI2022

Experimental screening of salt hydrates for thermochemical energy storage for building heating application

The selection of a suitable salt hydrate for use in a thermochemical energy storage system is challenging. In this work, the most promising salts to store intermediate heat energy were selected and tested. The criteria set are; volumetric energy density of >500 kWh m-3 with a dehydration temperature of <100 degrees C, material cost of <3.5 USD kg-1 (<15 USD kWh-1), melting does not occur during dehydration and safety. Based on that, the salt hydrates SrCl 2 , MgSO 4 , Na 3 PO 4 , MgCl 2 and SrBr 2 were selected and tested experimentally. A constant temperature and humidity chamber was used to measure moisture sorption of different salts. The hydration is investigated under the conditions of 20 degrees C and 20, 30, 40, 60 and 80% RH, while dehydration is investigated under the conditions of 70, 100 and 140 degrees C using an oven. These dehydration temperatures of <100 degrees C are suitable for solar application whereas the dehydration temperature of 140 degrees C is suitable for waste heat. Furthermore, the salts are cycled over 30 times under the hydration conditions of 20 degrees C, 60% RH with a dehydration temperature of 100 degrees C. From these results, it is concluded that SrCl 2 and SrBr 2 are the most promising salts. This study outlines both the advantages and disadvantages of each salt and states the conditions they are most suitable for.

25 ENERGY STORAGE↗
DOE OSTI2026

Phase change material-to-refrigerant heat exchangers: Experimental validation and uneven melting analysis

Thermal energy storage (TES) using phase change materials (PCMs) enables load shifting and reduces mismatches between the building's thermal demand and the heat pump (HP) system's thermal capacity. While most TES studies have focused on single-phase heat transfer fluids, PCM-to-refrigerant heat exchangers (PRHX), in which the refrigerant undergoes liquid-vapor phase change, remain largely underexplored. Here, to address this gap, this study systematically investigates a shell-and-tube PRHX operating as the condenser in an HP through experiments and simulations. A two-dimensional enthalpy-based finite-volume PRHX model was developed and validated against experimental data, including refrigerant and PCM temperature profiles, PRHX capacity, and system-level performance. Results show three characteristic stages: Stage I, the condenser temperature rapidly increases with PCM in the solid state absorbing sensible heat; Stage II, stable operation during PCM phase change; and Stage III, performance decline once part of the PCM becomes fully melted. Heat transfer analysis revealed that uneven PCM melting along the condenser length was driven primarily by variations in the refrigerant-side heat transfer coefficient, rather than local approach temperature differences. Further study demonstrated that minimizing refrigerant outlet subcooling led to more uniform PCM melting and extended Stages I and II by up to 89%. This paper provides a validated PRHX model, clarifies the mechanisms of uneven PCM melting, and highlights subcooling control as an effective strategy to improve TES performance in HP systems without requiring secondary loops.

Graphite matrix↗
DOE OSTI2023

Experimental investigation of power transient flow boiling

To advance the mechanistic understanding of power transients in flow boiling, experimental investigations are performed to capture the thermal response of four different kinds of cladding materials, including FeCrAls, to Fuchs reactivity initiated accident transients and linear ramp power transients. The transition boiling regime is phenomenologically reflected in power-transient flow boiling, which is different from steady-state boiling. In light of this, the critical heat flux that is usually featured with temperature overshooting does not indicate thermal safety margin of cladding materials as conservatively as the maximum heat flux, which is greater than critical heat flux in the power transient boiling curve. This is physically attributed to the thermal energy deposition on the cladding wall. In addition, the thermal energy released from the cladding wall results in different boiling heat transfer coefficient for the decreasing and increasing power stages respectively during the Fuchs power transient. The maximum heat flux difference gap, which appears due to changes in cladding materials and transient time scales, is appreciable under an intermediate heat convection regime. However, this difference gap is gradually weakened by the progressive increasing of mass flux and/or inlet subcooling due to the enhanced dominance of heat convection over heat conduction. Finally, the small difference gap of maximum heat flux is found to be insignificant under the weak heat convection because of power transient induced annular flow instability.

42 ENGINEERING↗
DOE OSTI2025

Experimental investigation of unsteady flow dynamics in therminol-66 using edge tone-induced oscillations

Recent research has demonstrated that flow oscillations induced by a wedge positioned opposite the jet outlet in edge tones can be effectively utilized for flow measurement purposes. This highlights the necessity for developing advanced instrumentation capable of precise flow measurements in experimental setups exposed to radiation and in challenging fluids such as molten salts. Here, this study contributes to the existing body of knowledge by conducting experiments using Therminol-66, an effective surrogate for FLiBe under appropriate temperature conditions for nuclear applications, across a broad range of Reynolds numbers from 17,700 to 555,000. Experiments were conducted with Therminol-66 at approximately 368.8 K under atmospheric pressure, with varying flow rates. A reliable correlation was established between the generated frequencies, corresponding flow rates, and device geometry parameters. The data were subjected to non-dimensional analysis to reveal the interrelationships among flow rate, fluid properties, device geometry, and their impact on the acoustic tones produced by the edge tone device. These findings contribute to the development of precise flow measurement instrumentation for use in challenging environments.

46 - INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AN↗
DOE OSTI2023

Vapor liquid equilibrium of pure and aqueous Methyl diethanolamine (MDEA), 2-Dimethylmonoethanolamine (DMMEA), N-Methylmonoethanolamine (MMEA) and 1-(2-Aminoethyl)piperazine (AEP): Experimental results and modeling

This work presents new vapor-liquid data for the pure components 2-dimethylmonoethanolamine (DMMEA) and N-methylethanolamine (MMEA) and for the binary systems of aqueous methyldiethanolamine (MDEA), DMMEA, MMEA, and 1-(2-aminoethyl)piperazine (AEP). New Antoine models are developed for the pure component systems, and new and improved NRTL models for the binary systems. In the model development, together with new data from this work, all available data on VLE, excess heat of mixing, H E , freezing point depression, and specific heat were gathered, evaluated and used selectively for parameter optimization. Emphasis has been put on a best possible representation of amine volatility to enable reasonable predictions of amine emissions from absorption plants and to form a basis for subsequent models of ternary systems with CO 2 . In conclusion, model predictions are compared with experimental results and other models, source by source, and the overall results are satisfactory.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗