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DOE OSTI2016

Final Technical Report: Using Solid Particles as Heat Transfer Fluid for use in Concentrating Solar Power (CSP) Plants

In today’s industrial economy, energy consumption has never been higher. Over the last 15 years the US alone has consumed an average of nearly 100 quadrillion BTUs per year [21]. A need for clean and renewable energy sources has become quite apparent. The SunShot Initiative is an ambitious effort taken on by the United States Department of Energy that targets the development of solar energy that is cost-competitive with other methods for generating electricity. Specifically, this work is concerned with the development of concentrating solar power plants (CSPs) with granular media as the heat transfer fluid (HTF) from the solar receiver. Unfortunately, the prediction of heat transfer in multiphase flows is not well understood. For this reason, our aim is to fundamentally advance the understanding of multiphase heat transfer, particularly in gas-solid flows, while providing quantitative input for the design of a near black body receiver (NBB) that uses solid grains (like sand) as the HTF. Over the course of this three-year project, a wide variety of contributions have been made to advance the state-of-the art description for non-radiative heat transfer in dense, gas-solid systems. Comparisons between a state-of-the-art continuum heat transfer model and discrete element method (DEM) simulations have been drawn. The results of these comparisons brought to light the limitations of the continuum model due to inherent assumptions in its derivation. A new continuum model was then developed for heat transfer at a solid boundary by rigorously accounting for the most dominant non-radiative heat transfer mechanism (particle-fluid-wall conduction). The new model is shown to be in excellent agreement with DEM data and captures the dependence of heat transfer on particle size, a dependency that previous continuum models were not capable of. DEM and the new continuum model were then employed to model heat transfer in a variety of receiver geometries. The results provided crucial feedback on the efficiency and feasibility of various designs. Namely, a prototype design consisting of an array of heated hexagonal tubes was later supplanted by a vertical conduit with internal baffles. Due to low solids heat transfer on the bottom faces of the hexagonal tubes in the prototype, the predicted wall temperature gradients exceeded the design limitations. By contrast, the vertical conduit can be constructed to continually force particle-wall contacts, and thus, result in more desirable solids heat transfer and wall temperature gradients. Finally, a new heat flux boundary condition was developed for DEM simulations to assess the aforementioned wall temperature gradients. The new boundary condition advances current state-of-the-art techniques by allowing the heat fluxes to each phase to vary with space and time while the total flux remains constant. Simulations with the new boundary condition show that the total boundary heat flux is in good agreement with the imposed total boundary heat flux. While the methods we have utilized here are primarily numerical and fundamental by nature, they offer some key advantages of: (i) being robust and valid over a large range of conditions, (ii) able to quickly explore large parameter spaces, and (iii) aid in the construction of experiments. We have ultimately leveraged our computational capabilities to provide feedback on the design of a CSP which possesses great potential to become a cost effective source of clean and renewable electricity. Overall, ensuring that future energy demands are met in a responsible and efficient manner has far reaching impacts that span both ecologic and economic concerns. Regarding logistics, the project was successfully re-negotiated after the go/no-decisions of Years 1 and 2. All milestones were successfully completed.

14 SOLAR ENERGY↗

DOE OSTI2020

Dendrite Growth Morphology Modeling in Liquid and Solid Electrolytes

The main goal of this project is to develop a multi-scale modeling approach that connects micron-scale phase-field models and atomic-scale density functional theory (DFT)-based simulations via parameter- and relationship-passing in order to predict Li-metal dendrite morphology evolution, in both liquid and solid electrolytes. The key hypothesis of the DFT-informed phase-field multiscale modeling approach is that it can capture the electrochemical-mechanical driving forces and incorporate the roles of nano-meter-thin solid electrolyte interphase (SEI) in liquid electrolytes as well as of the microstructures of micro-meter-thick solid electrolytes (SEs) for all-solid-state batteries. In this project, we have formulated and implemented phase-field models to incorporate the electrochemical driving forces in liquid electrolytes and then incorporate mechanical driving forces to simulate dendrite growth in solid electrolytes with resolved microstructures. We have implemented two treatments for the SEI: an explicit model to include the microstructure of the SE or SEI in the phase field model and an implicit model to simulate the impact of nano-meter thick SEI in liquid electrolytes by varying the electrode/electrolyte interfacial properties. The key interfacial properties, including the electronic and ionic transport properties, the charge transfer reaction kinetics, and mechanical properties, were computed by DFT-based calculations. At the DFT-based model, one key advancement is to directly predict the charge transfer reaction kinetics at a complex Li/SEI/electrolyte interface by linking DFT with density functional tight binding (DFTB) calculations. As the main accomplishments, we have demonstrated two successful predictions in both solid electrolyte and liquid electrolyte based on this multiscale approach. The predicted intergranular Li dendrite growth in LLZO revealed the importance of trapped electrons at internal interfaces in the microstructure of LLZO. The predicted electroplating morphology of mossy Li and faceted Mg agreed well with experiments. The insights provided by the multiscale model and the model enabled electrolyte and SEI design will accelerate the development of Li-metal electrode for high energy density batteries, that meet DOE’s target on cell density (>350 Wh/kg) and cost below $100/kWhuse for EV applications.

25 ENERGY STORAGE↗

DOE OSTI2020

First-principles Modeling and Design of Solid-State Interfaces for the Protection and Use of Lithium Metal Anodes

Li-ion batteries are one of the most advanced energy storage technologies in use today. Li-ion batteries are used in a multitude of applications ranging from consumer electronics, medical devices, sensors and grid storage. However, improving the capacity and energy density delivered by current Li-ion technology requires advanced materials research into novel chemical systems. In this project we have focused particularly in the use of solid-state electrolytes with lithium metal electrodes. Research into all solid-state batteries (ASSB) with Li metal electrodes has significantly expanded in recent years, however most studies reported experimental findings, which left substantial room for theoretical and modeling work as a tool to understand and determine design principles allowing reliable and safe use of ASSBs with Li metal. Among the remaining obstacles preventing reliable use of ASSBs with a Li metal electrode, the stability of the interface between the solid electrolyte and Li metal, and the propagation/dendrite formation of Li metal and resulting mechanical degradation of the electrolyte are key phenomenon that are yet to be fully understood. In the current project we have addressed these two coupled phenomena using first principles calculations and mesoscale continuum modeling. We have obtained chemical and electrochemical stability windows for several solid electrolyte materials. Additionally, from mathematical and numerical modeling of Li protrusion and dendrite initiation during plating and stripping we have determined design criteria in terms of chemical, electrochemical, and mechanical properties and operating conditions for which stable deposition can occur. We also considered the effects of mixed electronic-ionic conduction in solid electrolytes, which has more recently been suggested as another important mechanism involved in ASSB failure. Throughout our work we have successfully addressed important questions necessary for the use of ASSB’s. We have determined guiding principles for materials properties and operating conditions necessary to operate ASSB’s. And have proposed novel solid electrolyte materials with predicted chemical stability an ionic conductivity. Although this represents significant progress in our understanding, open questions remain in order to fully develop reliable and safely operate ASSBs with Li metal. Future work, building on this project will require further experimental, theoretical and simulation efforts to address remaining questions.

25 ENERGY STORAGE↗

DOE OSTI2023

Development of 3D Printing Techniques for Solid-State Lithium Batteries: Energy Storage Internship (Final Report)

The goal of this internship was to develop a solid polymer electrolyte with a suitable ionic conductivity and mechanical properties and integrate it with 3D printed cathode for solid state lithium batteries. While liquid electrolytes will have much higher conductivities and therefore higher power densities than solid electrolytes, batteries with such electrolytes suffer from extreme dendritic growth, short-circuiting, and general failure. Typically, batteries prevent this by including a solid yet porous separator somewhere between the anode and cathode to suppress dendritic growth. Solid polymer electrolyte acts as the conductive medium between electrodes as well as the separator that prevents failure from short-circuiting. The specific system explored is a vinyl ethylene carbonate (VEC) and polyethylene glycol diacrylate (PEGDA) mixed polymer solution using both 2,2’-azobis(2-methylpropionitrile) (AIBN) and Irgacure 819, respectively as thermal and photo- initiators. Electrochemical and rheological techniques were used to determine the optimal polymer solution and curing conditions. Through this research, multiple new pathways of exploration have been determined to create a usable solid polymer electrolyte through a combination of varying cure intensities and initiator concentrations.

25 ENERGY STORAGE↗

DOE OSTI2024

Solid State Li Ion Batteries Using Si Composite Anodes

Solid Power has teamed with Argonne National Laboratory (ANL) to develop an all solid-state lithium-ion battery (ASSB), enabled by a high-capacity Si anode and a solid state electrolyte (SSE). Replacing liquid electrolytes with solid electrolytes addresses the calendar life challenges that currently limit the widespread adoption of Si anodes. In this project, Si-SSE composite materials have been developed with a specific capacity >1500 mAh/g (at electrode level). A Si anode was coated by using a roll-to-roll process. All-solid-state NMC-Si pouch cells have been assembled and tested. Cycle life of 1100 at 100% DOD has been demonstrated in the solid state Si pouch cell. Excellent calendar life is achieved in the cell via a high temperature storage test.

25 ENERGY STORAGE↗

NASA NTRS1972

Solid lubricants: A survey

A survey is presented of the most recent developments and trends in the field of solid lubrication. Topics discussed include: a history of solid lubrication, lubricating solids, bonded lubricants, new developments, methods of evaluation, environmental effects, application methods, novel materials, and designs for the use of solid lubricants. Excerpts of solid lubricant specifications and a discussion of contact stresses imposed on specimens in three types of test machines used for the evaluation of solid lubricants are presented.

Campbell, M. E.↗

NASA NTRS1974

Testing and evaluation of solid lubricants for gas bearings

The testing and results of testing solid film lubricants for gas lubricated bearing applications are reported. The tests simulated operational hazards of tilting pad gas bearings. The presence of a low coefficient of friction and the endurance of the solid film lubricant were the criteria for judging superior performance. All solid lubricants tested were applied to a plasma sprayed chrome oxide surface. Molybdenum disulfide and graphite fluoride were the solid lubricants tested; other test parameters included the method of application of the solid lubricant and the surface finish of the plasma sprayed coating. In general, the application of a solid film lubricant was found to significantly improve the coefficient of friction of the rubbing surfaces.

Albrecht, P. R.↗

NASA NTRS1977

Review of the absorption spectra of solid O2 and N2 as they relate to contamination of a cooled infrared telescope

During contamination studies for the liquid helium cooled shuttle infrared telescope facility, a literature search was conducted to determine the absorption spectra of the solid state of homonuclear molecules of O2 and N2, and ascertain what laboratory measurements of the solid have been made in the infrared. With the inclusion of one unpublished spectrum, the absorption spectrum of the solid oxygen molecule has been thoroughly studied from visible to millimeter wavelengths. Only two lines appear in the solid that do not also appear in the gas or liquid. A similar result is implied for the solid nitrogen molecule because it also is homonuclear. The observed infrared absorption lines result from lattice modes of the alpha phase of the solid, and disappear at the warmer temperatures of the beta, gamma, and liquid phases. They are not observed from polycrystalline forms of O2, while strong scattering is. Scattering, rather than absorption, is considered to be the principal natural contamination problem for cooled infrared telescopes in low earth orbit.

Smith, S. M.↗

NASA NTRS1982

Ambient airborne solids concentrations including volcanic ash at Hanford, Washington sampling sites subsequent to the Mount St. Helens eruption

Airborne solids concentrations were measured on a near daily basis at two Hanford, Washington sites after the eruption of Mount St. Helens on May 18, 1980. These sites are about 211 km east of Mount St. Helens. Collected airborne solids included resuspended volcanic ash plus normal ambient solids. Average airborne solids concentrations were greater at the Hanford meteorological station sampling site which is 24 km northwest of the Horn Rapids dam sampling site. These increased concentrations reflect the sampling site proximity to greater ash fallout depths. Both sites are in low ash fallout areas although the Hanford meteorological station site is closer to the greater ash fallout areas. Airborne solids concentrations were decreased by rain, but airborne solids concentrations rapidly increased as surfaces dried. Airborne concentrations tended to become nearly the same at both sampling sites only for July 12 and 13.

Sehmel, G. A.↗

NASA NTRS1983

Effect of boundary layers on solid walls in three-dimensional subsonic wind tunnels

A linear method is developed which accounts for the effects of boundary layers on solid walls in subsonic three-dimensional wind tunnels. The streamwise gradient of the displacement thickness for a solid-wall boundary layer is expressed in terms of the von Karman momentum integral. The growth of the boundary layer due to the wall shearing stress is small compared to the variation caused by the model-induced pressure gradient. The viscous boundary condition can be expressed in terms of the edge velocity gradient and the gradient of the inviscid velocity potential function at the wall. Utilizing this analysis on the solid walls of several three-dimensional wind tunnel configurations shows that the most pronounced wall boundary-layer effect is on solid blockage for completely closed wind tunnels. For solid-wall tunnel configurations, the streamline curvature interference factor is reduced by a significant amount, while the lift interference factor at the model station does not depend on the boundary-layer parameter. For combination wall configurations, the slot effect of the horizontal walls dominates the viscous effect of the solid sidewalls.

Adcock, J. B.↗

NASA NTRS1984

Effect of boundary layers on solid walls in three-dimensional subsonic wind tunnels

A solution for the tunnel wall boundary layer effects for three-dimensional subsonic tunnels is presented. The model potentials are represented with simple singularities placed on the centerline of the tunnel and Laplace's equation in cylindrical coordinates is solved for either the conventional homogeneous slotted-wall boundary condition, the solid-wall viscous boundary condition, or a combination of them. The most pronounced wall boundary layer effect is on solid blockage for completely closed wind tunnels. Boundary layers on the wall reduce the blockage from the solid-wall, no-boundary-layer case in a manner similar to opening slots in a solid wall. Additionally, for solid-wall tunnel configurations, the streamline curvature interference factor is reduced by a significant amount, whereas the lift interference factor at the model station does not depend on the boundary layer parameter. For combination wall configurations, the slot effect of the horizontal walls dominates the viscous effect of the solid sidewalls.

Adcock, J. B.↗

NASA NTRS1985

Improving the Effectiveness of Integral Property Calculation in a CSG Solid Modeling System by Exploiting Predictability

Integral property calculation is an important application for solid modeling systems. Algorithms for computing integral properties for various solid representation schemes are fairly well known. It is important to deigners and users of solid modeling systems to understand the behavior of such algorithms. Specifically the trade-off between execution time and accuracy is critical to effective use of integral property calculation. The average behavior of two algorithms for Constructive Solid Geometry (CSG) representations is investigated. Experimental results from the PADL-2 solid modeling system show that coarse decompositions can be used to predict execution time and error estimates for finer decompositions. Exploiting this predictability allow effective use of the algorithms in a solid modeling system.

Clark, A. L.↗

NASA NTRS1990

Detailed modal testing of a solid rocket motor using a portable test system

Modern analytical techniques have expended the ability to evaluate solid rocket motors used in launch vehicles. As more detailed models of solid rocket motors were developed, testing methods were required to verify the models. Experimental modal analysis (modal testing) of space structures and launch vehicles has been a requirement for model validation for many years. However, previous testing of solid rocket motors has not typically involved dynamic modal testing of full scale motors for verification of solid propellant or system assembly properties. Innovative approaches to the testing of solid rocket motors were developed and modal testing of a full scale, two segment Titan 34D Solid Rocket Motor (SRM) was performed to validate detailed computer modeling. Special modifications were made to convert an existing facility into a temporary modal test facility which would accommodate the test article. The assembly of conventional data acquisition equipment into a multiple channel count portable system has made modal testing in the field feasible. Special purpose hydraulic exciters were configured to apply the dynamic driving forces required. All instrumentation and data collection equipment were installed at the test site for the duration of the test program and removed upon completion. Conversion of an existing test facility into a temporary modal test facility, and use of a multiple channel count portable test data acquisition system allowed all test objectives to be met and resulted in validation of the computer model in a minimum time.

Glozman, Vladimir↗

NASA NTRS1994

Composite Solid Electrolyte For Lithium Cells

Composite solid electrolyte material consists of very small particles, each coated with thin layer of Lil, bonded together with polymer electrolyte or other organic binder. Material offers significant advantages over other solid electrolytes in lithium cells and batteries. Features include high ionic conductivity and strength. Composite solid electrolyte expected to exhibit flexibility of polymeric electrolytes. Polymer in composite solid electrolyte serves two purposes: used as binder alone, conduction taking place only in AI2O3 particles coated with solid Lil; or used as both binder and polymeric electrolyte, providing ionic conductivity between solid particles that it binds together.

Peled, Emmanuel↗

NASA NTRS1993

Defects in electro-optically active polymer solids

There is considerable current interest in the application of organic and polymeric materials for electronic and photonic devices. The rapid, non-linear optical (NLO) response of these materials makes them attractive candidates for waveguides, interferometers, and frequency doublers. In order to realize the full potential of these systems, it is necessary to develop processing schemes which can fabricate these molecules into ordered arrangements. There is enormous potential for introducing well-defined, local variations in microstructure to control the photonic properties of organic materials by rational 'defect engineering.' This effort may eventually become as technologically important as the manipulation of the electronic structure of solid-state silicon based devices is at present. The success of this endeavor will require complimentary efforts in the synthesis, processing, and characterization of new materials. Detailed information about local microstructure will be necessary to understand the influence of symmetry breaking of the solid phases near point, line, and planar defects. In metallic and inorganic polycrystalline materials, defects play an important role in modifying macroscopic properties. To understand the influence of particular defects on the properties of materials, it has proven useful to isolate the defect by creating bicrystals between two-component single crystals. In this way the geometry of a grain boundary defect and its effect on macroscopic properties can be determined unambiguously. In crystalline polymers it would be valuable to establish a similar depth of understanding about the relationship between defect structure and macroscopic properties. Conventionally processed crystalline polymers have small crystallites (10-20 nm), which implies a large defect density in the solid state. Although this means that defects may play an important or even dominant role in crystalline or liquid crystalline polymer systems, it also makes it difficult to isolate the effect of a particular boundary on a macroscopically observed property. However, the development of solid-state and thin-film polymerization mechanisms have facilitated the synthesis of highly organized and ordered polymers. These systems provide a unique opportunity to isolate and investigate in detail the structure of covalently bonded solids near defects and the effect of these defects on the properties of the material. The study of defects in solid polymers has been the subject of a recent review (Martin, 1993).

Martin, David C.↗

NASA NTRS1959

Effects of Cross-Sectional Shape, Solidity, and Distribution of Heat-Transfer Coefficient on the Torsional Stiffness of Thin Wings Subjected to Aerodynamic Heating

A study has been made of the effects of varying the shape, solidity, and heat-transfer coefficient of thin wings with regard to their influence on the torsional-stiffness reduction induced by aerodynamic heating. The variations in airfoil shape include blunting, flattening, and combined blunting and flattening of a solid wing of symmetrical double-wedge cross section. Hollow double-wedge wings of constant skin thickness with and without internal webs also are considered. The effects of heat-transfer coefficients appropriate for laminar and turbulent flow are investigated in addition to a step transition along the chord from a lower to a higher constant value of heat-transfer coefficient. From the results given it is concluded that the flattening of a solid double wedge decreases the reduction in torsional stiffness while slight degrees of blunting increase the loss. The influence of chordwise variations in heat-transfer coefficient due to turbulent and laminar boundary-layer flow on the torsional stiffness of solid wings is negligible. The effect of a step transition in heat-transfer coefficient along the chord of a solid wing can, however, become appreciable. The torsional-stiffness reduction of multiweb and hollow double-wedge wings is substantially less than that calculated for a solid wing subjected to the same heating conditions.

Thomson, Robert G.↗

NASA NTRS2000

Modeling of Solid Waste Processing Options in BIO-Plex

BIO-Plex is a ground-based test bed currently under development by NASA for testing technologies and practices that may be utilized in future long-term life support missions. All aspects of such an Advanced Life Support (ALS) System must be considered to confidently construct a reliable system, which will not only allow the crew to survive in harsh environments, but allow the crew time to perform meaningful research. Effective handling of solid wastes is a critical aspect of the system, especially when recovery of resources contained in the waste is required. This is particularly important for ALS Systems configurations that include a Biomass Production Chamber. In these cases, significant amounts of inedible biomass waste may be produced, which can ultimately serve as a repository of necessary resources for sustaining life, notably carbon, water, and plant nutrients. Numerous biological and physicochemical solid waste processing options have been considered. Biological options include composting, aerobic digestion, and anaerobic digestion. Physicochemical options include pyrolysis, SCWO (supercritical water oxidation), various incineration configurations, microwave incineration, magnetically assisted gasification, and low temperature plasma reaction. Modeling of these options is a necessary step to assist in the design process. A previously developed top-level model of BIO-Plex implemented in MATLAB Simulink (r) for the use of systems analysis and design has been adopted for this analysis. Presently, this model only considered incineration for solid waste processing. Present work, reported here, includes the expansion of this model to include a wider array of solid waste processing options selected from the above options, bearing in mind potential, near term solid waste treatment systems. Furthermore, a trade study has also been performed among these solid waste processing technologies in an effort to determine the ideal technology for long-term life support missions.

Rodriguez, Luis F.↗

NASA NTRS2004

Lyophilization -Solid Waste Treatment

This paper discusses the development of a solid waste treatment system that has been designed for a Mars transit exploration mission. The technology described is an energy-efficient lyophilization technique that is designed to recover water from spacecraft solid wastes. Candidate wastes include feces, concentrated brines from water processors, and other solid wastes that contain free water. The system is designed to operate as a stand-alone process or to be integrated into the International Space Station Waste Collection System. In the lyophilization process, water in an aqueous waste is frozen and then sublimed, separating the waste into a dried solid material and liquid water. The sublimed water is then condensed in a solid ice phase and then melted to generate a liquid product. In the subject system the waste solids are contained within a 0.2 micron bio-guard bag and after drying are removed from the system and stored in a secondary container. This technology is ideally suited to applications such as the Mars Reference Mission, where water recovery rates approaching 100% are desirable but production of CO2 is not. The system is designed to minimize power consumption through the use of thermoelectric heat pumps. The results of preliminary testing of a prototype system and testing of the final configuration are provided. A mathematical model of the system is also described.

Litwiller, Eric↗