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DOE OSTI2024

Optimizing the Heisenberg Vortex Tube for Hydrogen Cooling (Final Technical Report)

Hydrogen utilization at Plug Power sites ranges between 70-93% with the remainder vented and lost to the atmosphere. The goal of this project was to improve hydrogen utilization at Plug Power fulfillment centers via the patented Heisenberg vortex tube (HVT). The HVT combines conventional counterflow vortex tubes with para-orthohydrogen conversion catalyst to allow the cooling of hydrogen flows with no moving parts or external energy inputs. In year 1 of this project the HVT was evaluated to improve hydrogen utilization via the following concepts: 1) increasing liquid hydrogen pump volumetric efficiency by 20% through vapor separation and subcooling of the liquid, 2) reducing liquid hydrogen storage tank boil-off losses by 20% through thermal vapor shielding (TVS), and 3) increase isentropic efficiency of supercritical hydrogen expansion at 40-50 K, from 31% to over 40%. The TVS concept was selected as the most favorable application for further development. While the conceptual analysis was underway, the cryocatalysis hydrogen experiment facility (CHEF) was retrofitted with a new cryocooler, higher pressure condenser tanks, and in-situ fiber-optic Raman probes for ortho-parahydrogen composition analysis at the inlets and outlets of the HVT. To our knowledge this is the first in-situ implementation of cryogenic Raman probes for ortho-parahydrogen analysis. Subsequent testing of catalyzed and non-catalyzed HVT identified a low flow rate, high-conversion efficacy regime well suited for TVS development. Computational fluid dynamics (CFD), Reduced order modeling (ROM), and quantum Monte Carlo atomistic simulations were applied to optimize the design of the HVT implemented for TVS. The simulations and analysis identified a ruthenium-based catalyst as the most optimal for high conversion with little pressure losses and was matched to experimental measurements. These results indicated the design could achieve the 20% boil-off reduction target. An HVT field-trial was designed and constructed by Plug Power and implemented at a customer site. However, budget limitations reduced the amount of catalyst that could be applied to the HVT. With the reduced amount of catalyst, CFD analysis estimated about 3% reduction in boil-off. A similar amount of boil-off reduction was observed during preliminary measurements during tank commissioning. However, the results have a large margin for error and were operated at relatively low tank temperatures when the HVT has the lowest potential for improvement. This project demonstrated the use of para-orthohydrogen catalysis for reducing liquid hydrogen tank boil-off losses. The field trial system is anticipated to provide long-term experimental measurements on tank operational performance that will allow Plug Power to instrument additional tanks in the future. Recommendations for future work include the development of higher activity, lower cost para-orthohydrogen conversion catalyst for use in the HVT. Tank process optimizations could maximize the efficacy of the HVT and further improve hydrogen utilization.

08 HYDROGEN↗

NASA NTRS2001

Modeling the Gas Dynamics Environment in a Subscale Solid Rocket Test Motor

Subscale test motors are often used for the evaluation of solid rocket motor component materials such as internal insulation. These motors are useful for characterizing insulation performance behavior, screening insulation material candidates and obtaining material thermal and ablative property design data. One of the primary challenges associated with using subscale motors however, is the uncertainty involved when extrapolating the results to full-scale motor conditions. These uncertainties are related to differences in such phenomena as turbulent flow behavior and boundary layer development, propellant particle interactions with the wall, insulation off-gas mixing and thermochemical reactions with the bulk flow, radiation levels, material response to the local environment, and other anomalous flow conditions. In addition to the need for better understanding of physical mechanisms, there is also a need to better understand how to best simulate these phenomena using numerical modeling approaches such as computational fluid dynamics (CFD). To better understand and model interactions between major phenomena in a subscale test motor, a numerical study of the internal flow environment of a representative motor was performed. Simulation of the environment included not only gas dynamics, but two-phase flow modeling of entrained alumina particles like those found in an aluminized propellant, and offgassing from wall surfaces similar to an ablating insulation material. This work represents a starting point for establishing the internal environment of a subscale test motor using comprehensive modeling techniques, and lays the groundwork for improving the understanding of the applicability of subscale test data to full-scale motors. It was found that grid resolution, and inclusion of phenomena in addition to gas dynamics, such as two-phase and multi-component gas composition are all important factors that can effect the overall flow field predictions.

Eaton, Andrew M.↗

NASA NTRS2007

Computational Plume Modeling of COnceptual ARES Vehicle Stage Tests

The plume-induced environment of a conceptual ARES V vehicle stage test at the NASA Stennis Space Center (NASA-SSC) was modeled using computational fluid dynamics (CFD). A full-scale multi-element grid was generated for the NASA-SSC B-2 test stand with the ARES V stage being located in a proposed off-center forward position. The plume produced by the ARES V main power plant (cluster of five RS-68 LOX/LH2 engines) was simulated using a multi-element flow solver - CRUNCH. The primary objective of this work was to obtain a fundamental understanding of the ARES V plume and its impingement characteristics on the B-2 flame-deflector. The location, size and shape of the impingement region were quantified along with the un-cooled deflector wall pressures, temperatures and incident heating rates. Issues with the proposed tests were identified and several of these addressed using the CFD methodology. The final results of this modeling effort will provide useful data and boundary conditions in upcoming engineering studies that are directed towards determining the required facility modifications for ensuring safe and reliable stage testing in support of the Constellation Program.

Allgood, Daniel C.↗

NASA NTRS2008

LOX/Methane Main Engine Igniter Tests and Modeling

The LOX/methane propellant combination is being considered for the Lunar Surface Access Module ascent main engine propulsion system. The proposed switch from the hypergolic propellants used in the Apollo lunar ascent engine to LOX/methane propellants requires the development of igniters capable of highly reliable performance in a lunar surface environment. An ignition test program was conducted that used an in-house designed LOX/methane spark torch igniter. The testing occurred in Cell 21 of the Research Combustion Laboratory to utilize its altitude capability to simulate a space vacuum environment. Approximately 750 ignition test were performed to evaluate the effects of methane purity, igniter body temperature, spark energy level and frequency, mixture ratio, flowrate, and igniter geometry on the ability to obtain successful ignitions. Ignitions were obtained down to an igniter body temperature of approximately 260 R with a 10 torr back-pressure. The data obtained is also being used to anchor a CFD based igniter model.

Breisacher, Kevin J.↗

DOE OSTI2025

Thermal Analysis of a Solid Particle Light-Trapping Planar Cavity Receiver Using Computational Fluid Dynamics

Concentrated solar power (CSP) is one of the most effective ways of harnessing solar power to create efficient, durable, and resilient energy systems. This study entails thermal modeling and analysis of a novel central tower receiver configuration. This receiver uses solid particles as the heat transfer fluid (HTF), a promising option for third-generation CSP systems. The configuration considered here is the light-trapping planar cavity receiver (LTPCR) introduced by the National Renewable Energy Laboratory. While heat transfer studies of various LTPCR subsystems have been done, system-level thermal analysis of the LTPCR receiver has not been attempted. This study also presents important sensitivity analyses of the operating parameters of the CSP system, which can help guide the design of future central tower receivers. This study employs Ansys Fluent as a computational fluid dynamics (CFD) tool to model fluid dynamics and heat transfer in the receiver, intending to quantify its thermal performance. The model seamlessly integrates Monte Carlo ray tracing data, which generates absorbed solar flux profiles from the heliostat field design, with the heat transfer characteristics of the fluidized particle bed. This unified model is designed to accurately predict the thermal behavior of the LTPCR. Analysis of preliminary results reveals that the primary loss mechanisms are radiative and natural convective losses, in that order. Based on observations from a baseline case, several strategies are suggested and numerically tested. These solutions include selective cooling of high-temperature regions and manipulation of particle bed parameters. Selective cooling of high-temperature regions reduced the peak temperature by 151 degrees C and decreased thermal losses by 0.9%. Improving the particle-wall heat transfer coefficient (P-W HTC) of the particle bed decreased the thermal losses by 1.7% and decreased the peak temperatures by 57 degrees C. Decreasing the particle inlet temperature (PIT) also reduced thermal losses by 3.5% and decreased peak temperatures by 29 degrees C. Compounding these strategies improved the thermal losses of the receiver from 13.5% in the baseline case to 7.5%. Additionally, the study explores the variation in thermal performance across different locations of the receiver, where a variation of thermal losses from 12.9% to 17.3% is found. This allows a comprehensive evaluation of potential improvements in efficiency and temperature management.

computational fluid dynamics↗

DOE OSTI2024

Testing- and Model- Based Optimization of Coal-fired Primary Heater Design for Indirect Supercritical CO 2 Power Cycles (Final Scientific and Technical Report)

The overall objective of this project was to perform the R&D necessary to mitigate the risk associated with the design of a primary heat exchanger for a solid-fired combustion system coupled with an indirect-fired closed-loop Brayton Cycle utilizing supercritical CO 2 . The key technological hurdle was the coupling of a solid-fuel firing system with the primary heater, which poses a singular challenge, which is the management of burner performance and operational conditions in a way to manage heat exchanger tube metal temperatures and temperature ramp rates in the absence of fluid phase change on the inside of the tubes. We designed and built the first ever pseudo power system employing a simple recuperated supercritical CO 2 closed-loop Brayton Cycle coupled to a solid-fuel fired system. Advanced coupled CFD and process modeling were used to design the primary heat exchanger (PHX), which consisted of both radiative and convective sections, to limit tube metal temperatures resulting from the heat release profile of the solid fuel flame near the radiative tubes. The heat exchanger was designed to produce finished CO 2 temperatures of 600 °C a pressure of 20.7 MPa and CO 2 flow of 5.5 kg/s. The constructed PHX was capable of 1.2 MWth heat uptake. During design of the PHX, the modeling showed that most variables influencing flame shape (burner stoichiometric ratio and register velocities and swirl) were not suitable to manage heat flux to the metal surfaces. This is because they substantially increased adiabatic flame temperature through the influence of localized stoichiometric ratio. Excess air and firing rate were the two most powerful variables that could be used to control tube surface temperatures. The coupled system was operated for a total of 407 hours, with the longest continuous run of 248 hours. For 62% of the operational time, the unit was unmanned and in automatic control. The fuels used for the testing included natural gas, two Utah Bituminous coals, woody biomass, and bagasse. During the testing we were able to verify the 1.2 MWth heat uptake and we operated at a finished CO 2 temperature of 607 °C and a pressure of 20.3 MPa simultaneously. The real-time corrosion rate of the Super 304H tube CO 2 surface in the region of the radiative section of the PHX were measured, at an approximate temperature of 550 °C. The two key variables related to corrosion rate are the pressure and flow rate of the CO 2 . A technoeconomic analysis was performed at a scale of 120 MWE. The updated analysis showed that the efficiency of an sCO 2 power producing plant will be related to the pressure drop of the PHX.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2024

High- and Mid-Fidelity Modeling Comparison for a Floating Marine Turbine System: Preprint

There is a lack of suitable numerical tools, particularly open-source tools, that can be used for designing and optimizing marine turbine systems. The National Renewable Energy Laboratory (NREL) has added features to their widely used mid-fidelity wind turbine modeling code, OpenFAST, to enable modeling of axial flow marine turbines. This necessitated the addition of several physical effects relevant to marine turbines that can be neglected for wind turbines. These include buoyant loads, added mass and inertia loads, wave-current superposition, and changes to the coordinate systems. This updated version of OpenFAST allows for the modeling of both fixed and floating marine turbine systems at a speed comparable to real time. While efficient for long simulations, large sets of load cases, and design studies, mid-fidelity codes cannot capture all of the potentially important physical phenomenon impacting marine turbine systems. High-fidelity computational fluid dynamics (CFD) simulations can capture more flow effects with fewer assumptions and provide detailed body pressure mapping and flow-field information. It is important to compare predictions between mid-fidelity and high-fidelity codes, both to verify the models and to understand the limitations. A floating marine turbine system designed by NREL was modeled both with OpenFAST and with the commercial CFD code, STARCCM+. The CFD model used a 3-D unsteady Reynolds-averaged Navier-Stokes solver for a volume-of-fluid numerical wave and current tank. The blade-resolved simulations used the sliding-interface technique for the spinning rotor and an overset grid to accommodate the rigid-body motion of the floating system. The mooring system was modelled with a custom coupling of the CFD solver with the open-source code, MoorDyn. This improves upon the existing quasi-static catenary solver in STARCCM+, which lacks seabed contact or line-to-line connections. Spatial and temporal convergence studies were conducted. The simulation results for a combined current and wave condition are compared between OpenFAST and CFD, highlighting the capabilities of the mid-fidelity code and identifying the areas where a high-fidelity approach is needed.

CFD↗

NASA NTRS2006

Validation of Multi-Dimensional Stirling Engine Design Codes: Measurements in the 90-Degree Turn Test Section

The work to be presented herein was motivated largely by a desire to improve the understanding of oscillatory fluid mechanics inside a Stirling engine. To this end, a CFD project was undertaken at Cleveland State University with the goal of accurately predicting the fluid dynamics within an engine or engine component. Along with the CFD efforts, a code validation project was undertaken at the University of Minnesota. The material covered herein consists of four main parts. In section 1, an experimental investigation of a small aspect ratio impinging jet is discussed. Included in this discussion is a description of the test facilities and instrumentation. A presentation of the collected data is given and comments are made. Next, in section 2, a parallel experimental investigation is presented in which the same geometry as that of section 1 is used, but the flow conditions are changed from steady unidirectional flow to sinusoidally oscillating flow. In section Two, collected data are presented and comments are made. In section 3, a comparison is made between the results of sections 1 and 2, namely, sinusoidally oscillating flow results are compared to steady, unidirectional flow results from the same geometry. Finally, in section 4, a comparison is made between experimentally collected data (the main subject of this work) and CFD generated results. Furthermore, in appendix A, an introductory description of the primary measurement tool used in the experimental process the hot wire anemometer is given for the unfamiliar. The anemometer calibration procedure is described in appendix B. A portfolio of data reduction and data processing codes is provided in appendix C and lastly, a DVD and a roadmap of its contents is provided in an appendix D. 1.0 Unidirectional Flow Investigations 1.1 Introduction This unidirectional experimental program was undertaken to complement an oscillatory flow investigation conducted at the University of Minnesota. The oscillatory investigation is discussed thoroughly in section 2. We defer the description of the motivation behind these experiments until the introduction of section 2. The work that is discussed in this thesis began (chronologically) with oscillatory flow visualization experiments. It was decided that it would be valuable and important to investigate the flow under unidirectional conditions in the same geometry as that of the oscillatory experiments. The thought was that the unidirectional case would be less complicated to model with a CFD program (a moving boundary would be replaced with a steady state boundary condition). Thus, a series of unidirectional experiments were carried out to capture the important features of the flow within the test section. The purpose of these experiments was to provide a data set for comparison to CFD generated velocity fields. Hot-wire anemometry data were taken and flow visualization was conducted as a standard for code validation. The flow geometry was simple, such that it could be easily gridded in a CFD program. However, the geometry provided separation and transition zones, shear layers and recirculation zones. These characteristics made the flow complex and challenging for CFD computation. We comment that the order of experiments that produced this report is as follows: experimental flow visualization under oscillatory flow conditions was carried out; this was followed by unidirectional flow visualization and hot wire anemometry; finally, oscillatory hot wire anemometry was conducted. We present the results out of chronological order for the following reason: the unidirectional results are easier

Simon, Terrence W.↗

DOE OSTI2020

Progress Toward Simulating Departure from Nucleate Boiling at High-Pressure Applications with Selected Wall Boiling Closures

Recently, a Eulerian-based two-fluid computational fluid dynamics (CFD) framework with a wall heat flux partitioning approach has been intensively investigated for departure from nucleate boiling (DNB) simulation under the U.S. Department of Energy–funded Consortium for Advanced Simulation of Light Water Reactors (CASL) program. Understanding of the DNB characteristics over a range of pressurized water reactor–like operating conditions and accurate prediction of boiling crisis in the nuclear power system have been grand challenges because of the large impact of DNB on reactor safety and operational economics. The ultimate goal of this task in the CASL program is to introduce a robust multiphase CFD–based DNB modeling framework that is capable of characterizing an entire boiling history in which the wall boiling mode experiences the following through multiple stages of heat transfer mode: (1) single-phase convective heat transfer, (2) nucleate boiling heat transfer, and (3) identification of the departure of nucleate boiling. To validate the CASL boiling model, we have benchmarked simulated DNB over three different flow channel configurations (pipe flow, 5 × 5 fuel bundle with mixing vane tests, and 5 × 5 fuel bundle without mixing vane tests) against experimental measurements, and the validation result with open literature is reported. The DNB detection criteria in the simulation are checked by monitoring the peak wall temperature, wall dryout factor, and net energy balance. In addition to the DNB performance test, some preliminary sensitivity results on closure model selection are reported to address the prediction capability of local void profile against measurements. The boiling simulation tested in this study exhibits a maximum deviation of 24% from the measured DNB value in a high-pressure (i.e., 138 bars) subcooled pipe flow test. The ranges of operating conditions are as follows: 1650 to 2650 kg/m 2 ·s for mass flux and 8.5 to 96 K for subcooled inlet temperature. The deviation is even reduced to 7% when the subcooled temperature is less than 40 K. Besides accuracy, base practice guidelines for DNB detection criteria are tested by monitoring three simulation variables: (1) maximum wall temperature, (2) wall dryout factor (i.e., K-value), and (3) energy balance. Numerical robustness of DNB simulation is largely achieved in most of the validation test except for a few high subcooled test cases.

42 ENGINEERING↗

NASA NTRS1985

A study of the compatibility of an existing CFD package with a broader class of material constitutions

The flexibility of the PHOENICS computational fluid dynamics package was assessed along two general avenues; parallel modeling and analog modeling. In parallel modeling the dependent and independent variables retain their identity within some scaling factors, even though the boundary conditions and especially the constitutive relations do not correspond to any realistic fluid dynamic situation. PHOENICS was used to generate a CFD model that should exhibit the physical anomalies of a granular medium and permit reasonable similarity with boundary conditions typical to membrane or porous piston loading. A considerable portion of the study was spent prying into the existing code with a prejudice toward rate type and disarming any inherent fluid behavior. The final stages of the study were directed at the more specific problem of multiaxis loading of cylindrical geometry with a concern for the appearance of bulging, cross slab shear failure modes.

French, K. W., Jr.↗

DOE OSTI2022

Correction to: Investigating the rheology of fluidized and non-fluidized gas-particle beds: implications for the dynamics of geophysical flows and substrate entrainment

We report natural geophysical mass flows are among the most complex granular systems and their dynamics are often modified by the presence of an interstitial fluid. Prediction of their runout requires the development of models estimating the solid stresses in these hazardous currents wherein excess pore-fluid pressure can develop. We use discrete element modelling (DEM-CFD) with a Coarse-Graining post-processing technique (CG) to investigate the rheology of unsteady gas-particle fluidized to non-fluidized granular beds placed on horizontal and inclined planes. Similar to fluidized beds immersed in viscous fluids, the effective friction coefficient of air-fluidized beds can be defined as a function of the classic μ(I)-rheology and the non-dimensional fluid or solid pressure to explain the failure and dynamics of granular flows with excess pore pressure on inclines. However, dilation imposed by fluid drag and particle collisions in gas-particle fluidized beds can drastically change its effective frictional properties. In contrast with the common assumption in water-particle flows that granular temperature is negligible, in our gas-particle simulations, the contribution of the velocity fluctuations to the stress tensor is significant. Hence, the shear stress is found to be non-zero even when the flow is fully fluidized in the inertial regime. These results suggest the need to better understand velocity fluctuations to predict the effective viscosity of sheared fluidized mixtures and are relevant for many applications. Notably, a unified approach is useful for many geophysical flows that encompass a range of fluidization conditions in a single flow such as pyroclastic density currents and snow avalanches.

58 GEOSCIENCES↗

DOE OSTI2021

Meta-uncertainty for particle image velocimetry

Uncertainty quantification for Particle Image Velocimetry (PIV) is critical for comparing experimentally measured flow fields with Computational Fluid Dynamics (CFD) results, and model design and validation. However, PIV features a complex measurement chain with coupled, non-linear error sources, and quantifying the uncertainty is challenging. Multiple assessments show that none of the current methods can reliably measure the actual uncertainty across a wide range of experiments, and estimates can vary. Because the current methods differ in assumptions regarding the measurement process and calculation procedures, it is not clear which method is best to use for an experiment where the error distribution is unknown. To address this issue, we propose a method to estimate an uncertainty method's sensitivity and reliability, termed the Meta-Uncertainty. The novel approach is automated, local, and instantaneous, and based on perturbation of the recorded particle images. We developed an image perturbation scheme based on adding random unmatched particles to the interrogation window pair considering the signal-to-noise (SNR) of the correlation plane. Each uncertainty scheme's response to several trials of random particle addition is used to estimate a reliability metric, defined as the rate of change of the inter-quartile range (IQR) of the uncertainties with increasing levels of particle addition. We also propose applying the meta-uncertainty as a weighting metric to combine uncertainty estimates from individual schemes, based on ideas from the consensus forecasting literature. We use planar and stereo PIV measurements across a range of canonical flows to assess the performance of the uncertainty schemes. Further, a novel method is introduced to assess an uncertainty scheme's performance based on a quantile comparison of the error and uncertainty distributions, generalizing the current method of comparing the RMS of the two distributions. Here, the results show that the combined uncertainty method outperforms the individual methods, and this work establishes the meta-uncertainty as a useful reliability assessment tool for PIV uncertainty quantification.

47 OTHER INSTRUMENTATION↗

DOE OSTI2020

Spray Combustion and Soot Formation

Mitigating particulate matter (PM) emissions while simultaneously controlling nitrogen oxide and hydrocarbon emissions is critical for both gasoline and diesel engines. The problem is especially critical during cold-start cycles where aftertreatment devices are less effective. Understanding how liquid sprays and films form PM and designing to change the outcome requires advanced combustion concepts developed through joint experimental and computational efforts. However, existing spray and soot computational models are oversimplified and non-physical, and are therefore unable to reliably capture quantitative or even qualitative trends over a wide range of engine operating conditions. This task involves the development and application of advanced optical diagnostics and high-pressure gas and particle sampling/analysis in unique high-temperature, high-pressure vessels to investigate spray dynamics and soot formation with the objective of providing fundamental understanding about soot processes under relevant engine conditions to aid the development of improved soot models for commercial CFD codes

02 PETROLEUM↗

DOE OSTI2022

Pilot Testing of a Highly Efficient Pre-combustion Sorbent-based Carbon Capture System

TDA developed and demonstrated a highly efficient pre-combustion carbon capture system. The overall objective of this work was to develop a new sorbent-based pre-combustion carbon capture technology for Integrated Gasification Combined Cycle (IGCC) power plants. In this project our goal was to demonstrate the techno-economic viability of the new technology by 1) demonstrating it in large-scale slipstream tests, and 2) carrying out a high fidelity engineering and cost analysis. TDA’s process used an advanced physical adsorbent that selectively removes CO 2 from coal-derived synthesis gas above the dew point of the gas at temperatures as high as 300°C. The sorbent consists of a mesoporous carbon whose surface was grafted with functional groups that remove CO 2 via a well-known acid-base interaction. As documented in bench-scale experiments and field tests with actual coal gas, the sorbent achieved a very high capacity for CO 2 at temperatures as high as 300°C. The sorbent bound CO 2 more strongly than common physical adsorbents, providing the chemical potential needed for the high temperature operation. However, because CO 2 does not form a true covalent bond with the surface sites (as is the case with chemical absorbents), the sorbent regeneration could be carried out with only a very small energy input. The heat input to regenerate our sorbent was only 4.9 kcal per mol of CO 2 , which is much lower than that for chemical absorbents (e.g., 29.9 kcal/mol CO 2 for sodium carbonate) and was similar to the requirements of physical solvents (e.g., 4 kcal/mol CO 2 for Selexol TM ). Because the sorbent operates above the dew point of the synthesis gas (unlike the Selexol TM process), a higher power cycle efficiency can be achieved. With previous DOE/NETL funding (Contract No. DE-FE-0000469), we demonstrated the techno-economic viability of the technology in bench-scale tests and slipstream demonstrations at the National Carbon Capture Center (NCCC), Wilsonville, Alabama and Wabash River IGCC plant in Terra Haute, Indiana. We demonstrated a stable working CO 2 capacity for over 11,650 cycles with simulated synthesis gas. We also evaluated its performance with actual synthesis gas in two test campaigns at the Wabash River IGCC Plant, Terre Haute, IN and the National Carbon Capture Center (NCCC), Wilsonville, AL. The slipstream tests clearly showed that the actual coal gas constituents and potential contaminants (e.g. trace metals, halides, tars) had no effect on the sorbent’s ability to remove CO 2 (the same sorbent beds were used in both field tests with no sign of deactivation for 2,000 cycles with over 26,750 SCF of gas treated). As expected, due to the high temperature CO 2 removal capability and low energy needed to regenerate the sorbent, the power cycle efficiency with our process was greater than 34% on a higher heating value (HHV) basis; in comparison, the same IGCC plant equipped with the Selexol TM solvent for carbon capture can only achieve 31.4% HHV efficiency. The capital cost for an IGCC system with TDA’s process is estimated as $2,417/kW e , which is 12% lower than that of the IGCC/ Selexol TM process. The levelized cost for electricity including the transport, storage and monitoring (TS&M) cost for CO 2 was calculated as $\$ $92.9/MWh (lowest reported to our knowledge), which is much better than the $105.2/MWh estimated for the IGCC/ Selexol TM process. In this project (DE-FE0013105), TDA Research, in collaboration with our partners Gas Technology Institute (GTI), Illinois Clean Coal Institute (ICCI), University of California, Irvine (UCI), University of Alberta (UOA), Siemens, NCCC and Sinopec advanced the technical maturity of the technology; scaling it up by a factor of 100. We optimized the reactor design using computational fluid dynamics (CFD); using adsorption modeling we improved the pressure swing adsorption (PSA) cycle sequence. We carried out two field test campaigns with a fully-equipped 0.1 MW e prototype unit (for a total of 844 hours) using actual synthesis gas to prove the viability of the new technology. A successful 30 day (707 hrs) evaluation was completed at NCCC under air blown gasification conditions. We demonstrated 97.3% carbon capture at 1,500 SLPM, 93% carbon capture at 1,800 SLPM, and 90% carbon capture at 2,100 SLPM in the NCCC tests. We also demonstrated the system for 137 hours at a Sinopec petrochemical plant under oxygen blown gasification, demonstrating 86% carbon capture at 2,660 SLPM. In collaboration with University of California, Irvine (UCI), we completed a techno-economic analysis (TEA) for TDA’s warm gas cleanup technology integrated to IGCC power plant. The net plant efficiencies (on a coal HHV basis) for the warm gas cleanup cases were estimated to be 34.0% for E-GasTM gasifier, 34.4% for GE gasifier, 33.4 for the Shell gasifier and 34.2 for the TRIG TM gasifier (Cases 2, 4, 6 and 8 in this study) with a catalytic combustor for CO 2 purification, which are significantly higher than those for the Cold Gas Case, or an increase of as much as 12% in the heat rate for Case 2, 6% for Case 4, 9% for Case 6, and 9% for Case 8. The 1st year cost of electricity with the transport, storage and monitoring (TS&M) costs for the CO 2 included was $\$ $129.2/MWh for the E-GasTM gasifier Warm Gas Cleanup Case, $\$ $131.9/MWh for the GE gasifier Warm Gas Cleanup Case, $\$ $146.8/MWh for the Shell Gasifier Warm Gas Cleanup Case, and $\$ $129.9/MWh for the TRIG TM gasifier Warm Gas Cleanup Case. For comparison, the costs for the baseline Cold Gas CO 2 removal with Selexol for the different gasifiers were: $\$ $146.6/MWh for the E-Gas TM gasifier, $\$ $142.2/MWh for the GE gasifier, $\$ $159.0/MWh for the Shell gasifier and $\$ $144.3/MWh for the TRIG TM gasifier. In summary, the costs for our system were 7 to 12% lower than the corresponding Cold Gas Cleanup cases. The results of this techno-economic analysis suggested that TDA’s high temperature PSA-based Warm Gas Clean-up Technology can make a substantial improvement in the IGCC plant thermal performance for achieving near zero CO 2 emissions for E-Gas TM , GE, Shell and TRIG TM gasifier based IGCC power plants. The capital expenses were estimated to be lower than that of Selexol’s™. Taken together, the higher net plant efficiency and lower capital and operating costs resulted in substantial reduction in the cost of carbon capture for the IGCC plant equipped with TDA’s high temperature PSA-based carbon capture system. Finally, in collaboration with Gas Technology Institute (GTI) we completed the environmental health and safety assessment for TDA’s warm gas carbon capture technology.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2024

Numerical study on aerosol sampling in a nuclear facility duct with a 90-degree elbow

Due to the challenging design requirements, elbows are often unavoidable in duct configuration, and these 90-degree bends introduce swirl, velocity variations, recirculation, and secondary flow. These disturbances make it difficult for nuclear facilities to meet particle sampling standards. A series of numerical analyses are conducted to track aerosols in a nuclear facility duct having a 90-degree elbow with the assistance of computational fluid dynamics (CFD). A turbulence model, a continuity, and a momentum, a discrete phase model, and species transport equations are solved simultaneously to track aerosols in the duct. The effect of turbulence models, turbulent dispersion models, droplet drag model, aerosol amount, aerosol spray configuration, guide vanes, and mixers are investigated. Simulation results are analyzed per relevant testing codes such as DOE-HDBK-1169, ASME AG1, ISO 14644-3, ACGIH, and ANSI/HPS N13.1.

Han, Kai [Savannah River Nuclear Solutions (SRNS),↗

DOE OSTI2021

Techno-Economic Optimization of CSP Plants with Free-Falling Particle Receivers

Particle receivers are one of the candidates for the next generation of CSP plants, whose goal is to reduce the levelized cost of electricity (LCOE) to 0.05 $/kWh. This paper presents a techno-economic analysis to study if a CSP system with free-falling particle receiver can achieve this goal. The plant analyzed integrates two ground-based bins to store the excess energy and a supercritical CO2 cycle to generate electricity. The model used for the analysis presents several upgrades to previous particle systems models in order to increase its fidelity, accuracy, and representativeness of an actual system. The main upgrades are the addition of off-design conditions during the annual simulations in all the components and an improved receiver model validated against CFD simulations. The size of the main components is optimized to obtain the system configuration with minimum LCOE. The results show that particle CSP systems can reduce the LCOE to 0.056 $/kWh if the configuration is composed of 1.61 × 106 m2 of heliostats, a 250 m high tower with a 537 m2 falling particle curtain, and 16 h thermal energy storage.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2020

Simulating Fracture Sealing by Granular LCM Particles in Geothermal Drilling

Lost circulation occurs when the returned fluid is less than what is pumped into the well due to loss of fluid to pores or fractures. A lost-circulation event is a common occurrence in a geothermal well. Typical geothermal reservoirs are often under-pressured and have larger fracture apertures. A severe lost-circulation event is costly and may lead to stuck pipe, well instability, and well abandonment. One typical treatment is adding lost-circulation materials (LCMs) to seal fractures. Conventional LCMs fail to properly seal fractures because their mechanical limit is exceeded at elevated temperatures. In this paper, parametric studies in numerical simulations are conducted to better understand different thermal effects on the sealing mechanisms of LCMs. The computational fluid dynamics (CFDs) and the discrete element method (DEM) are coupled to accurately capture the true physics of sealing by granular materials. Due to computational limits, the traditional Eulerian–Eulerian approach treats solid particles as a group of continuum matter. With the advance of modern computational power, particle bridging is achievable with DEM to track individual particles by modeling their interactive forces between each other. Particle–fluid interactions can be modeled by coupling CFD algorithms. Fracture sealing capability is investigated by studying the effect of four individual properties including fluid viscosity, particle size, friction coefficient, and Young’s modulus. It is found that thermally degraded properties lead to inefficient fracture sealing.

15 GEOTHERMAL ENERGY↗

DOE OSTI2023

Ignition Delay Test with Spray & Combustion Vessel

Ignition delay test results of different fuels (RON60, RON70, RON80, RON90, and biofuel blends) under different engine operating conditions with a multi-hole injector. These results were used to better understand the spray and combustion characteristics and validate the CFD real fuel model (https://doi.org/10.5281/zenodo.8432075). This work was part of the DOE funded project (DE-EE0008478; Co-optimized Mixed-Mode Engine and Fuel Demonstrator for Improved Fuel Economy while Meeting Emissions Requirements; https://doi.org/10.2172/1887341).

02 PETROLEUM↗