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All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Advanced sorbents for modular oxygen production for REMS gasifiers

Under a DOE funded effort, Thermosolv LLC has been developing a sorbent-based oxygen production technology for gasification and oxy-combustion applications. The sorbents utilize oxygen-storage properties of certain perovskites to (1) selectively adsorb oxygen at moderate temperature from compressed air and (2) release the adsorbed oxygen into a vacuum or a sweep gas such as CO2 and/or steam. Through cyclic operations of multiple sorbent beds such a process can be made continuous. Pressure drop across the sorbent bed and other similar design considerations dictate that the sorbent be in the form of a high surface-area-to-volume pellet and yet still possess sufficient crush strength and integrity. Process efficiency is determined by the sorption and desorption kinetics and sorbent capacity. Typical process involves cycle times in the order of 100 seconds, a time too short to fully utilize the full volume of the sorbent and the sorption capacity of the sorbent pellets. As a part of this project, Thermosolv LLC undertook the development of oxygen sorbents as a high-surface area supported sorbent on a light-weight inert support to (1) reduce the cost, (2) increase the productivity, and (3) reduce the overall weight of the reactor. Using a previously developed perovskite (LSCF 1991) with its well-characterized performance, composite sorbent pellets each consisting of an inert core coated by a thin layer of the functional perovskite material were produced. Several low-density, inexpensive inert solids supports in the 1/8”-1/4” size were selected to keep the pressure drop across the sorbent bed in the acceptable range. A number of commercial technologies including spray coating, dip coating, incipient impregnation of porous substrate followed by thermal annealing at various temperatures and duration were employed and tested to produce robust composite supported sorbent pellets. A sense of optimum coating thickness was developed by testing sorbent pellets of various increasing diameter pellets. LSCF-1991extrudates ranging in size from 1/32” to 3/16” were tested in a TGA and in a fixed-bed pressure swing test set-up for sorption/desorption cycles of interest. The data show that for the operational conditions of interest the coating thickness for a supported sorbent pellet needs to be approximately 1/32” (about 0.8 mm). Subsequent work thereby concentrated on developing composite pellets of various substrates, shapes and sizes with coating layer of about this size range. Candidate support materials were chosen based on cost, inertness, mechanical strength, thermal expansion and chemical stability with sorbent material, and in a size range to give an acceptable pressure drop in fixed-bad reactor configurations. Coating application methods used for application of the sorbent onto the support included precipitation, spray coating and dip coating from sorbent slurries and sol gels. For all coated supports where we could successfully apply a uniform coating of desired thickness with an acceptable handling performance in terms of exfoliation, TGA-based cyclic sorption/desorption testing was performed to determine cycling capacity of oxygen. Among nearly twenty different support materials tested, best adhesion performance was obtained from stainless saddle supports. In the bench-scale fixed-bad tests stainless steel saddle support composite pellets with a coating thickness in the 0.6 mm or so range, the composite sorbent pellet performance approached up to 95% of that of the 2 mm parent material pellets. In a parallel approach to reducing the cost of the sorbent, alternate sorbent formulations replacing/reducing the amount of cobalt in the LSCF family were also investigated. Successful formulations that could match the performance of LSCF 1991 were identified based on TGA cyclic tests as LSCF 1919 and LSF 1910. In the range of operational envelop of cycle times and other relevant process operating conditions, the reduced Co formulations showed comparable performance in the bench-scale fixed-bad cyclic operations. As a part of this project, we also attempted substitution of La and Sr with Ca and Ba, and Co with Mn, Ni and Cu with little success, but the overall project goal of reducing sorbent cost in terms of raw material and manufacturing expenses was successful.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2026

Development and Application of High-Fidelity Models for Heterogeneous CO2 Frost Formation

Carbon America has developed a cryogenic carbon capture technology ("FrostCC") that separates CO2 from point source emissions by solidifying it at cold temperatures through preferential desublimation. Cooling is achieved through a series of interlinked compression, heat exchange, and expansion operations. In the current system, frosting of CO2 happens in heat exchangers, followed by CO2 recovery in a separate extraction step. In this work, multiphysics computational fluid dynamics (CFD) models are developed and validated for compressible and low Mach flows to simulate the formation of solid CO2 in flue gas flowing in a heat exchanger geometry. The models track the mass transfer rate of CO2 from gas phase to solid phase, heat released from desublimation, and the evolution of the solid CO2 layer. Simulations are used to answer scientific questions related to the angle of heat exchanger pipes, where buoyancy effects from flow velocity and pipe orientation influence CO2 frosting. Results show that upwardly angled pipes produce notably different flow structures compared to horizontal or vertical configurations, and that carbon capture efficiency correlates with buoyancy effects for pipe angles within plus or minus 23 degrees of horizontal.

97 MATHEMATICS AND COMPUTING↗
NASA NTRS1980

An artificial energy method for calculating flows with shocks

The artificial-viscosity method, first proposed by von Neumann and Richtmyer, introduces an artificial viscous pressure term in regions of compression such that an increase in entropy occurs in shock transition zones. The paper describes how dissipative flows can be induced by reducing the total energy available for adiabatic processes in shock zones. A class of inviscid fluid flows, called semiflows, is described in which the flows exhibit thermodynamic differences. Induced dissipative flows modify the pressure in regions of compression in a manner analogous to the artificial-viscosity method and for a gas, the effect is equivalent to suitably modifying the gas constant in the equation of state. By employing MacCormack's method and the usual non-adiabatic equations, numerical solutions of a Riemann problem are compared with the modified artificial energy method, showing that the dissipation effect predicted by the analytical formulation is reflected in the numerical method as well.

Rose, M. E.↗
NASA NTRS1984

A kinky heliospheric current sheet - Cause of CDAW-6 substorms

Two magnetospheric substorms and the intensification of the second are caused by interplanetary magnetic field and ram pressure changes associated with a kinky heliospheric current sheet (KHCS). The responsible interplanetary features occur in a highly compressed region between a solar flare-associated shock wave and the cold driver gas. The possibility that the interplanetary structure is a 'magnetic cloud' is ruled out.

Tsurutani, B. T.↗
NASA NTRS1989

Integrated Heat Switch/Oxide Sorption Compressor

Thermally-driven, nonmechanical compressor uses container filled with compressed praseodymium cerium oxide powder (PrCeOx) to provide high-pressure flow of oxygen gas for driving closed-cycle Joule-Thomson-expansion refrigeration unit. Integrated heat switch/oxide sorption compressor has no moving parts except check valves, which control flow of oxygen gas between compressor and closed-cycle Joule-Thomson refrigeration system. Oxygen expelled from sorbent at high pressure by evacuating heat-switch gap and turning on heater.

Bard, Steven↗
NASA NTRS1989

Toward a CFD nose-to-tail capability - Hypersonic unsteady Navier-Stokes code validation

Computational fluid dynamics (CFD) research for hypersonic flows presents new problems in code validation because of the added complexity of the physical models. This paper surveys code validation procedures applicable to hypersonic flow models that include real gas effects. The current status of hypersonic CFD flow analysis is assessed with the Compressible Navier-Stokes (CNS) code as a case study. The methods of code validation discussed to beyond comparison with experimental data to include comparisons with other codes and formulations, component analyses, and estimation of numerical errors. Current results indicate that predicting hypersonic flows of perfect gases and equilibrium air are well in hand. Pressure, shock location, and integrated quantities are relatively easy to predict accurately, while surface quantities such as heat transfer are more sensitive to the solution procedure. Modeling transition to turbulence needs refinement, though preliminary results are promising.

Edwards, Thomas A.↗
NASA NTRS1987

The validation of numerical computations

Information is given in viewgraph form on the validation of computational fluid dynamics codes. Topics covered include the types of validation required, aerodynamic heating to a slender 5 degree cone, heat transfer on cones with isentropic compression surfaces, the validation of turbulence data, modeling of thermodynamic and transport properties, real gas code validation, the Flight Dynamics Laboratory validation efforts, and reacting gas experimental data in low density flow.

Buck, Melvin L.↗
NASA NTRS1995

General Fluid System Simulation Program to Model Secondary Flows in Turbomachinery

The complexity and variety of turbomachinery flow circuits created a need for a general fluid system simulation program for test data anomaly resolution as well as design review. The objective of the paper is to present a computer program that has been developed to support Marshall Space Flight Center's turbomachinery internal flow analysis efforts. The computer program solves for the mass. energy and species conservation equation at each node and flow rate equation at each branch of the network by a novel numerical procedure which is a combination of both Newton-Ralphson and successive substitution method and uses a thermodynamic property program for computing real gas properties. A generalized, robust, modular, and 'user-friendly' computer program has been developed to model internal flow rates, pressures, temperatures, concentrations of gas mixtures and axial thrusts. The program can be used for any network for compressible and incompressible flows, choked flow, change of phase and gaseous mixturecs. The code has been validated by comparing the predictions with Space Shuttle Main Engine test data.

Majumdar, Alok K.↗
NASA NTRS2015

Development of the US3D Code for Advanced Compressible and Reacting Flow Simulations

Aerothermodynamics and hypersonic flows involve complex multi-disciplinary physics, including finite-rate gas-phase kinetics, finite-rate internal energy relaxation, gas-surface interactions with finite-rate oxidation and sublimation, transition to turbulence, large-scale unsteadiness, shock-boundary layer interactions, fluid-structure interactions, and thermal protection system ablation and thermal response. Many of the flows have a large range of length and time scales, requiring large computational grids, implicit time integration, and large solution run times. The University of Minnesota NASA US3D code was designed for the simulation of these complex, highly-coupled flows. It has many of the features of the well-established DPLR code, but uses unstructured grids and has many advanced numerical capabilities and physical models for multi-physics problems. The main capabilities of the code are described, the physical modeling approaches are discussed, the different types of numerical flux functions and time integration approaches are outlined, and the parallelization strategy is overviewed. Comparisons between US3D and the NASA DPLR code are presented, and several advanced simulations are presented to illustrate some of novel features of the code.

CFD↗
NASA NTRSDate not supplied

TechEdSat 7, 10, 13, 15: Exo-brake Experiments on the ISS, First Virgin Orbit, and First Firefly-Alpha Test Flights.

The TechEdSat flight series (TES-n), developed by the Nano Orbital Workshop (NOW) group at NASA Ames, has been studying cube satellite re-entry technologies with a focus on Exo-Brake drag device research. An exo-atmospheric braking device, the Exo-Brake uses the tenuous upper atmosphere acting in a free molecular flow regime to enable controllable adjustment of the drag profile of the host spacecraft, currently enabling rapid disposal of small spacecraft after mission conclusion, and eventual targeted de-orbit to a desired entry point at the Von Karman line, or approximately 100km in altitude. The TES-7 mission, flown on the first successful Virgin Orbit flight January 17, 2021, was injected into a 500km, 61-degree inclination orbit, with an expected orbital lifetime of approximately ten years. After successful deployment of a unique hydrogen gas-cell inflation design ‘disposal’-type Mylar Exo-Brake intended to rapidly de-orbit the spacecraft, the maximum expected orbital lifetime of the TES-7 spacecraft was successfully reduced from ten years to 1.3 years, an 87% reduction in orbit lifetime via a passive, fuel-less system. The subsequent TES-13 mission utilized a new, less complex ‘disposal’-type Exo-Brake design made from collapsible rigid struts rather than inflated struts to reduce the engineering, construction, and safety complexities introduced by the prior hydrogen gas inflation design. The rigid strut Exo-Brake design is stowed via rotational compression and deploys using only stored spring energy once released via electronic actuator. This new rotation compression storage design has become the new Exo-Brake design standard used on TES missions thanks to its simplicity. Following on the success of this new Exo-Brake design demonstrated by TES-13, the design was further refined to enabled active manipulation of the Exo-Brake effective drag area though a winch-like system. Both the TES-10 and TES-15 spacecraft were equipped with geometrically similar Exo-Brake devices capable of such active drag modulation, with the intent of studying the operational impact of having such devices on cube satellite missions. To increase the survival time of the Exo-Brake at low altitudes and thus gain more experiment time and better guidance capability, TES-15 was equipped with a modulated Exo-Brake constructed from 3M™ Nextel™ 440 ceramic oxide fiber, the same fabric material used in the Space Shuttle TPS system, rather than Mylar. After launching on Alpha Flight 2 October 1st, 2022, Firefly’s first successful launch, TES-15 met the same modulation restrictions as TES-10, with modulation prohibited above 200km to avoid possible collision with other spacecraft. In this case, a low deployment orbit caused an extremely short mission life, which, coupled with delayed spacecraft identification, exacerbated collision concerns and caused performance data of the high-temperature Exo-Brake design to be inconclusive. As such, the Nano Orbital Workshop has taken a new approach of only conducting modulated Exo-Brake research on missions deploying below ISS altitude to avoid collision avoidance restrictions, and is working to improve spacecraft identification and location reporting techniques to increase experiment durations. Upcoming TES mission will therefore use one of two classes of Exo-Brake depending on their target altitude, as to be described in the submission.

M Murbach↗
NASA NTRSDate not supplied

TechEdSat 7, 10, 13, 15: Exo-brake Experiments on the ISS, First Virgin Orbit, and First Firefly-Alpha Test Flights

The TechEdSat flight series (TES-n), developed by the Nano Orbital Workshop (NOW) group at NASA Ames, has been studying cube satellite re-entry technologies with a focus on Exo-Brake drag device research. An exo-atmospheric braking device, the Exo-Brake uses the tenuous upper atmosphere acting in a free molecular flow regime to enable controllable adjustment of the drag profile of the host spacecraft, currently enabling rapid disposal of small spacecraft after mission conclusion, and eventual targeted de-orbit to a desired entry point at the Von Karman line, or approximately 100km in altitude. The TES-7 mission, flown on the first successful Virgin Orbit flight January 17, 2021, was injected into a 500km, 61-degree inclination orbit, with an expected orbital lifetime of approximately ten years. After successful deployment of a unique hydrogen gas-cell inflation design ‘disposal’-type Mylar Exo-Brake intended to rapidly de-orbit the spacecraft, the maximum expected orbital lifetime of the TES-7 spacecraft was successfully reduced from ten years to 1.3 years, an 87% reduction in orbit lifetime via a passive, fuel-less system. The subsequent TES-13 mission utilized a new, less complex ‘disposal’-type Exo-Brake design made from collapsible rigid struts rather than inflated struts to reduce the engineering, construction, and safety complexities introduced by the prior hydrogen gas inflation design. The rigid strut Exo-Brake design is stowed via rotational compression and deploys using only stored spring energy once released via electronic actuator. This new rotation compression storage design has become the new Exo-Brake design standard used on TES missions thanks to its simplicity. Following on the success of this new Exo-Brake design demonstrated by TES-13, the design was further refined to enabled active manipulation of the Exo-Brake effective drag area though a winch-like system. Both the TES-10 and TES-15 spacecraft were equipped with geometrically similar Exo-Brake devices capable of such active drag modulation, with the intent of studying the operational impact of having such devices on cube satellite missions. To increase the survival time of the Exo-Brake at low altitudes and thus gain more experiment time and better guidance capability, TES-15 was equipped with a modulated Exo-Brake constructed from 3M™ Nextel™ 440 ceramic oxide fiber, the same fabric material used in the Space Shuttle TPS system, rather than Mylar. After launching on Alpha Flight 2 October 1st, 2022, Firefly’s first successful launch, TES-15 met the same modulation restrictions as TES-10, with modulation prohibited above 200km to avoid possible collision with other spacecraft. In this case, a low deployment orbit caused an extremely short mission life, which, coupled with delayed spacecraft identification, exacerbated collision concerns and caused performance data of the high-temperature Exo-Brake design to be inconclusive. As such, the Nano Orbital Workshop has taken a new approach of only conducting modulated Exo-Brake research on missions deploying below ISS altitude to avoid collision avoidance restrictions, and is working to improve spacecraft identification and location reporting techniques to increase experiment durations. Upcoming TES mission will therefore use one of two classes of Exo-Brake depending on their target altitude, as to be described in the submission.

Marcus Murbach↗
DOE OSTI2021

Process for retrofitting an industrial gas turbine engine for increased power and efficiency

A process for retrofitting an industrial gas turbine engine of a power plant where an old industrial engine with a high spool has a new low spool with a low pressure turbine that drives a low pressure compressor using exhaust gas from the high pressure turbine, and where the new low pressure compressor delivers compressed air through a new compressed air line to the high pressure compressor through a new inlet added to the high pressure compressor. The old electric generator is replaced with a new generator having around twice the electrical power production. One or more stages of vanes and blades are removed from the high pressure compressor to optimally match a pressure ratio split. Closed loop cooling of one or more new stages of vanes and blades in the high pressure turbine is added and the spent cooling air is discharged into the combustor.

Jones, Russell B.↗
DOE OSTI2022

Metal Hydride Compressor for High-Pressure (875 bar) Hydrogen Delivery

Metal hydride hydrogen compression utilizes a reversible heat-driven interaction of a hydride-forming metal alloy with hydrogen gas. This paper reports on the development of a laboratory scale two-stage Metal Hydride Compressor (MHC) system with a feed pressure of 150 bar delivering high purity H2 gas at outlet pressures up to 875 bar. Stage 1 and stage 2 AB 2 metal hydrides are identified based on experimental characterization of the pressure-composition-temperature (PCT) behavior of candidate materials. The selected metal hydrides are each combined with expanded natural graphite, increasing the thermal conductivity of the composites by an order of magnitude. These composites are integrated in two compressor beds with internal heat exchangers that alternate between hydrogenation and dehydrogenation cycles by thermally cycling between 20 °C and 150 °C. The prototype compressor achieved compression of hydrogen from 150 bar to 700 bar with an average flow rate of 33.6 g/hr.

08 HYDROGEN↗
NASA NTRS2002

Development of a Next-Generation Membrane-Integrated Adsorption Processor for CO2 Removal and Compression for Closed-Loop Air Revitalization Systems

The current CO2 removal technology of NASA is very energy intensive and contains many non-optimized subsystems. This paper discusses the concept of a next-generation, membrane integrated, adsorption processor for CO2 removal nd compression in closed-loop air revitalization systems. This processor will use many times less power than NASA's current CO2 removal technology and will be capable of maintaining a lower CO2 concentration in the cabin than that can be achieved by the existing CO2 removal systems. The compact, consolidated, configuration of gas dryer, CO2 separator, and CO2 compressor will allow continuous recycling of humid air in the cabin and supply of compressed CO2 to the reduction unit for oxygen recovery. The device has potential application to the International Space Station and future, long duration, transit, and planetary missions.

Mulloth, Lila↗
NASA NTRS2016

Mars Molniya Orbit Atmospheric Resource Mining

This NIAC (NASA Advanced Innovative Concepts) work will focus on Mars and will build on previous efforts at analyzing atmospheric mining at Earth and the outer solar system. Spacecraft systems concepts will be evaluated and traded, to assess feasibility. However the study will primarily examine the architecture and associated missions to explore the closure, constraints and critical parameters through sensitivity studies. The Mars atmosphere consists of 95.5 percent CO2 gas which can be converted to methane fuel (CH4) and Oxidizer (O2) for chemical rocket propulsion, if hydrogen is transported from electrolyzed water on the Mars surface or from Earth. By using a highly elliptical Mars Molniya style orbit, the CO2 atmosphere can be scooped, ram-compressed and stored while the spacecraft dips into the Mars atmosphere at periapsis. Successive orbits result in additional scooping of CO2 gas, which also serves to aerobrake the spacecraft, resulting in a decaying Molniya orbit.

mining↗
NASA NTRS2005

Development of a Low-Power CO2 Removal and Compression System for Closed-Loop Air Revitalization in Future Spacecraft

The current CO2 removal technology of NASA is very energy intensive and contains many non-optimized subsystems. This paper discusses the design and prototype development of a two-stage CO2 removal and compression system that will utilize much less power than NASA s current CO2 removal technology. This integrated system contains a Nafion membrane followed by a residual water adsorber that performs the function of the desiccant beds in the four-bed molecular sieve (4BMS) system of the International Space Station (ISS). The membrane and the water adsorber are followed by a two-stage CO2 removal and compression subsystem that satisfies the operations of the CO2 adsorbent beds of the 4BMS aid the interface compressor for the Sabatier reactor connection. The two-stage compressor will utilize the principles of temperature-swing adsorption (TSA) compression technology for CO2 removal and compression. The similarities in operation and cycle times of the CO2 removal (first stage) and compression (second stage) operations will allow thermal coupling of the processes to maximize the efficiency of the system. In addition to the low-power advantage, this processor will maintain a lower CO2 concentration in the cabin than that can be achieved by the existing CO2 removal systems. The compact, consolidated, configuration of membrane gas dryer and CO2 separator and compressor will allow continuous recycling of humid air in the cabin and supply of compressed CO2 to the reduction unit for oxygen recovery. The device has potential application to the International Space Station and future, long duration, transit, and planetary missions.

Mulloth, Lila M.↗
DOE OSTI2023

Techno-Economic Optimization of Advanced Energy Plants with Integrated Thermal, Mechanical, and Electro-Chemical Storage (Final Report)

The increasing use of renewable energy sources is leading to increased cycling of fossil-fueled power plants (FFPP) that are designed to operate at base-loaded conditions. Integrating energy storage facilities with the FFPPs can be helpful in reducing load-following operation of FFPPs. Decentralized deployment of energy storage facilities at the FFPP level has considerable advantages due to possibilities of smaller storage capacities, immediate benefits realized by the host power plant due to the increase in the efficiency, cleaner emission and higher plant life to name a few. Most importantly, deployment at the FFPP level can exploit the existing equipment items and facilities at the host power plant, thus reducing the CAPEX and reducing the storage capacity. However, realization of these benefits will critically depend on novel configuration/integration strategies with the least impact on the power plant operation and its configuration. Furthermore, dynamics of the entire integrated system including both the FFPP and the storage technologies must be taken into account to obtain the cost-optimal solution. With these motivations, the objective of this project was to complete a focused evaluation of decentralized deployments of energy storage facilities at the FFPP level. Promising thermal, chemical, mechanical, and electro-chemical storage technologies were evaluated with due consideration of their transient response to obtain various optimal system concepts that can minimize the levelized cost of storage. For thermal storage, cryogenic energy storage along with high temperature heat storage in molten salt as well as phase change material were evaluated. For mechanical storage, cryogenic air storage and pumped hydro storages were evaluated. For chemical storage, hydrogen storage was evaluated. For electrochemical storage, the team evaluated sodium sulfur, vanadium redox flow battery as well as Li-ion batteries. Integration of these storage technologies with the natural gas combined cycle (NGCC) and supercritical pulverized coal (SCPC) plants was considered. Six technologies, namely molten salt, cryogenics, compressed air, pumped hydro, H2 storage and Li-ion battery storage, were downselected based on their levelized cost of storage. It was observed that the ranking of the optimal storage technology can differ based on the host power plant technology even when same demand/supply/price profile for electricity are considered. It was also observed that as the variability in power demand varies, the ranking of the optimal storage technologies vary. However, for the same demand and LMP profile, top six optimal storage technologies for NGCC vs SCPC plants did not differ much even though LCOS for the same technology and optimal size of a given storage technology did differ. Detailed techno-economic assessment of these six technologies was undertaken.

01 COAL, LIGNITE, AND PEAT↗