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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
DOE OSTI2014

Event-by-event direct photon anisotropic flow in relativistic heavy-ion collisions

Here, we consider directly emitted and hadronic decay photons from event-by-event hydrodynamic simulations. We compute the direct photon anisotropic flow coe cients and compare with recent experimental measurements. We find that it is crucial to include the photon multiplicity as a weighting factor in the definition of $v^γ_n$. We also investigate the sensitivity of the direct photon spectrum and elliptic flow to the theoretical uncertainty of the photon emission rate in the quark-hadron transition region and to the pre-equilibrium dynamics of relativistic heavy-ion collisions.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2019

Techno-Economic Analysis of an Intensified Integrated Gasification Combined Cycle (IGCC) Power Plant Featuring a Combined Membrane Reactor - Adsorptive Reactor (MR-AR) System

In this work, the novel concept of a combined membrane-adsorptive reactor sequence (MRAR) is developed and implemented in an Integrated Gasification Combined Cycle (IGCC) plant. This novel MR-AR IGCC plant is subsequently analyzed from an economic viewpoint through a techno-economic analysis (TEA) of the proposed plant. This novel design can achieve over 90% carbon capture without the use of a Dual-Stage Selexol unit. The resultant intensified design is more efficient from both an economic and power production perspective than the traditional IGCC plants with pre-combustion Carbon-Capture Storage (CCS) technology. The COMSOL software package is utilized to simulate the MR-AR sequence proposed in this work, and the UNISIM software (HoneywellTM) is used to create an intensified process flowsheet of the proposed MR-AR IGCC plant, which is subsequently heat-integrated. The TEA developed for the MR-AR IGCC power plant will be used to identify the extent of process intensification the proposed design has over the traditional IGCC plants with pre-combustion CCS. Furthermore, the results demonstrate a reduction in both the cost-of-electricity (COE) and in the capital cost of the proposed design over the baseline case.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2014

Process for CO2 Capture Using Ionic Liquid That Exhibits Phase Change

A novel process for capturing carbon dioxide from the flue gas of a coal-fired power plant has been shown to reduce parasitic power consumption substantially. The process employs an ionic liquid created at the University of Notre Dame that has a high capacity for absorbing CO2 by chemical reaction. A distinguishing property of this ionic liquid is that it changes phase from solid to liquid upon reaction with CO2. The process uses heat generated by this phase transition to lower parasitic power consumption. The driving force for CO2 separation is a combination of temperature and pressure differences; the process could even work without the addition of heat. A realistic process was created to capture CO2 efficiently. Computer simulation of the process enabled calculation of viable process conditions and power usage. The main concepts of the process were shown to work using a lab-scale apparatus. Parasitic power consumes 23% of net power generation, 55% lower than that of the monoethanolamine (MEA) process. However, capital cost is higher. The cost of electricity (COE) is 28% lower than that of the MEA process.

Eisinger, RS↗
DOE OSTI2014

The Seebeck Coefficient and Phonon Drag in Silicon

We present a theory of the phonon-drag Seebeck coe cient in nondegenerate semiconductors, and apply it to silicon for temperatures 30 < T < 300K. Our calculation uses only parameters from the literature, and previous calculations of the phonon lifetime. We nd excellent agreement with the measurements of Geballe and Hull [Phys.Rev. 98, 940 (1955)]. The phonon-drag term dominates at low temperature, and shows an important dependence on the dimensions of the experimental sample.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Optimization of an in Vitro CYP450 Induction Assay Using Cryopreserved Cell Lines

Cytochrome P450 (CYP450) enzymes are responsible for the majority for Phase I metabolism. Induction occurs when a drug increases the rate of CYP450 enzyme production. As a result, the rates of metabolism of subsequent drugs increase, posing concerns for dosing and safety. To further expand the USAMRICD Absorption, Distribution, Metabolism, Excretion, and Toxicity Center of Excellence (ADMET CoE) profiling capabilities, a CYP450 induction assay is being developed using alternative cell lines to primary human hepatocytes to measure changes in gene expression of CYP1A2 and CYP3A4 isoenzymes. Primary human hepatocytes are the gold standard for evaluating P450 induction in vitro ; however, they have inherent limitations such as high costs, fastidious nature, and significant lot‐to‐lot variability. Induction assessments using cryopreserved hepatocytes and two immortalized cell lines, HepaRG and HepatoCells, are being conducted to determine a more robust, cost‐effective alternative model. Each cell line was exposed to the standard inducers rifampicin and omeprazole to assess CYP3A4 and CYP1A2 activity, respectively. Following a 72‐hour incubation period, RNA from the cell cultures was extracted and purified. Fold changes of gene expression were measured using real‐time quantitative PCR (RT‐qPCR). Hepatocytes displayed an average fold change of 92.7 for CYP3A4 and 49.6 for CYP1A2, whereas HepaRG displayed changes of 28.6 and 179.5, respectively. Average values for CYP3A4 and CYP1A2 for HepatoCells were 58.7 and 43.9. Based on the data, HepatoCells most closely mimicked cryopreserved hepatocytes in comparison to HepaRG cells. Additional data on assay parameters and technique optimization will be presented. Support or Funding Information Opinion disclaimer: The views expressed in this abstract are those of the authors and do not reflect the official policy of the Department of the Army, Department of Defense, or the U.S. Government. This project was generously supported in part by an appointment to the Postgraduate Research Participation Program at the U.S. Army Medical Research Institute of Chemical Defense administered by the Oak Ridge Institute for Science and Education through an interagency agreement between the U.S. Department of Energy and U.S. Army Medical Research and Materiel Command. Support is also provided by the Defense Threat Reduction Agency – Joint Science and Technology Office, Medical S&T Division. This abstract is from the Experimental Biology 2019 Meeting. There is no full text article associated with this abstract published in The FASEB Journal .

Lim, Tae Young↗
DOE OSTI2021

Performance of Hybrid Renewable Energy Power System for a Residential Building

Using fossil fuels as the primary way to generate electricity causes a significant effect on the environment. In 2019, more than 64% of the electricity in the United States of America was generated using fossil-fuel resources, while renewable energy (RE) resources contributed to only 17% of the U.S. electricity generation for the same year. Additionally, due to the complex terrain distribution of many states in the U.S., a massive opportunity of utilizing RE resources in rural and remote areas can reduce the cost of electrical grid installation for such areas. In this study, a typical residential building with an average energy utilization of 30.25 kWh/day with a demand peak of 5.34 kW was considered a case study in each state to optimize a hybrid RE system and find the best alternative electrical grid system. This study presents the best configuration between solar and wind energy with different types of energy storage. It was discovered the photovoltaic (PV) solar panels—diesel generators with battery best services in all states. The daily radiation and diesel prices substantially affect the levelized cost of energy (COE) values in each state.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2013

A Novel System for Carbon Dioxide Capture Utilizing Electrochemical Membrane Technology

FuelCell Energy, Inc. (FCE), in collaboration with Pacific Northwest National Laboratory (PNNL) and URS Corporation, is developing a novel Combined Electric Power and Carbon-Dioxide Separation (CEPACS) system, under a contract from the U.S. Department of Energy (DE-FE0007634), to efficiently and cost effectively separate carbon dioxide from the emissions of existing coal fired power plants. The CEPACS system is based on FCE’s electrochemical membrane (ECM) technology utilizing the Company’s internal reforming carbonate fuel cell products carrying the trade name of Direct FuelCell® (DFC®). The unique chemistry of carbonate fuel cells offers an innovative approach for separation of CO2 from existing fossil-fuel power plant exhaust streams (flue gases). The ECM-based CEPACS system has the potential to become a transformational CO2-separation technology by working as two devices in one: it separates the CO2 from the exhaust of other plants such as an existing coal-fired plant and simultaneously produces clean and environmentally benign (green) electric power at high efficiency using a supplementary fuel. The overall objective of this project is to successfully demonstrate the ability of FCE’s electrochemical membrane-based CEPACS system technology to separate ≥ 90% of the CO2 from a simulated Pulverized Coal (PC) power plant flue-gas stream and to compress the captured CO2 to a state that can be easily transported for sequestration or beneficial use. Also, a key project objective is to show, through a Technical and Economic Feasibility Study and bench scale testing (11.7 m2 area ECM), that the electrochemical membrane-based CEPACS system is an economical alternative for CO2 capture in PC power plants, and that it meets DOE objectives for the incremental cost of electricity (COE) for post-combustion CO2 capture.

direct fuel cells↗
DOE OSTI2017

Optimal damping profile ratios for stabilization of perfectly matched layers in general anisotropic media

Conventional perfectly matched layers (PML) can be unstable for certain kinds of anisotropic media. Multi-axial PML removes such instability using nonzero damping coe cients in the directions tangential with the PML interface. While using non-zero damping pro le ratios can stabilize PML, it is important to obtain the smallest possible damping pro le ratios to minimize arti cial re ections caused by these non-zero ratios, particularly for 3D general anisotropic media. Using the eigenvectors of the PML system matrix, we develop a straightforward and e cient numerical algorithm to determine the optimal damping pro le ratios to stabilize PML in 2D and 3D general anisotropic media. Numerical examples show that our algorithm provides optimal damping pro le ratios to ensure the stability of PML and complex-frequency-shifted PML for elastic-wave modeling in 2D and 3D general anisotropic media.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2013

Novel Solvent System for Post Combustion CO{sub 2} Capture

The purpose of this project was to evaluate the performance of ION’s lead solvent and determine if ION’s solvent candidate could potentially meet DOE’s target of achieving 90% CO{sub 2} Capture from a 550 MWe Pulverized Coal Plant without resulting in an increase in COE greater than 35%. In this project, ION’s lead solvent demonstrated a 65% reduction in regeneration energy and a simultaneous 35% reduction in liquid to gas ratio (L/G) in comparison to aqMEA at 90% CO{sub 2} capture using actual flue gas at 0.2 MWe. Results have clearly demonstrated that the ION technology is in line with DOE performance expectations and has the potential to meet DOE’s performance targets in larger scale testing environments.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2015

Mitigation of Syngas Cooler Plugging and Fouling

This Final Report summarizes research performed to develop a technology to mitigate the plugging and fouling that occurs in the syngas cooler used in many Integrated Gasification Combined Cycle (IGCC) plants. The syngas cooler is a firetube heat exchanger located downstream of the gasifier. It offers high thermal efficiency, but its’ reliability has generally been lower than other process equipment in the gasification island. The buildup of ash deposits that form on the fireside surfaces in the syngas cooler (i.e., fouling) lead to reduced equipment life and increased maintenance costs. Our approach to address this problem is that fouling of the syngas cooler cannot be eliminated, but it can be better managed. The research program was funded by DOE using two budget periods: Budget Period 1 (BP1) and Budget Period 2 (BP2). The project used a combination of laboratory scale experiments, analysis of syngas cooler deposits, modeling and guidance from industry to develop a better understanding of fouling mechanisms and to develop and evaluate strategies to mitigate syngas cooler fouling and thereby improve syngas cooler performance. The work effort in BP 1 and BP 2 focused on developing a better understanding of the mechanisms that lead to syngas cooler plugging and fouling and investigating promising concepts to mitigate syngas cooler plugging and fouling. The work effort focused on the following: • analysis of syngas cooler deposits and fuels provided by an IGCC plant collaborating with this project; • performing Jet cleaning tests in the University of Utah Laminar Entrained Flow Reactor to determine the bond strength between an ash deposit to a metal plate, as well as implementing planned equipment modifications to the University of Utah Laminar Entrained Flow Reactor and the one ton per day, pressurized Pilot Scale Gasifier; • performing Computational Fluid Dynamic modeling of industrially relevant syngas cooler configurations to develop a better understanding of deposit formation mechanisms; • performing Techno-Economic-Analysis for a representative IGCC plant to investigate the impact on plant economics, in particular the impacts on the Cost of Electricity (COE), due to plant shutdowns caused by syngas cooler plugging and fouling and potential benefits to plant economics of developing strategies to mitigate syngas cooler fouling; and • performing modeling and pilot scale tests to investigate the potential benefits of using a sorbent (fuel additive) to capture the vaporized metals that result in syngas cooler fouling. All project milestones for BP 1 and BP 2 were achieved. DOE was provided a briefing on our accomplishments in BP1 and BP2 and our proposed plans for Budget Period 3 (BP 3). Based on our research the mitigation technology selected to investigate in BP 3 was the use of a sorbent that can be injected into the gasifier with the fuel slurry to capture vaporized metals that lead to the deposit formation in the syngas cooler. The work effort proposed for BP 3 would have focused on addressing concerns raised by gasification industry personnel for the impacts on gasifier performance of sorbent injection, so that at the end of BP 3 the use of sorbent injection would be at “pre-commercial” stage and ready for use in a Field Demonstration that could be funded by industry or DOE. A Budget Continuation Application (BCA) was submitted to obtain funding for BP3 DOE but DOE chose to not fund the proposed BP3 effort.

47 OTHER INSTRUMENTATION↗
DOE OSTI2015

An In-Depth Analysis of the Chung-Lu Model

In the classic Erd}os R enyi random graph model [5] each edge is chosen with uniform probability and the degree distribution is binomial, limiting the number of graphs that can be modeled using the Erd}os R enyi framework [10]. The Chung-Lu model [1, 2, 3] is an extension of the Erd}os R enyi model that allows for more general degree distributions. The probability of each edge is no longer uniform and is a function of a user-supplied degree sequence, which by design is the expected degree sequence of the model. This property makes it an easy model to work with theoretically and since the Chung-Lu model is a special case of a random graph model with a given degree sequence, many of its properties are well known and have been studied extensively [2, 3, 13, 8, 9]. It is also an attractive null model for many real-world networks, particularly those with power-law degree distributions and it is sometimes used as a benchmark for comparison with other graph generators despite some of its limitations [12, 11]. We know for example, that the average clustering coe cient is too low relative to most real world networks. As well, measures of a nity are also too low relative to most real-world networks of interest. However, despite these limitations or perhaps because of them, the Chung-Lu model provides a basis for comparing new graph models.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2016

DOE Centers of Excellence Performance Portability Meeting

Performance portability is a phrase often used, but not well understood. The DOE is deploying systems at all of the major facilities across ASCR and ASC that are forcing application developers to confront head-on the challenges of running applications across these diverse systems. With GPU-based systems at the OLCF and LLNL, and Phi-based systems landing at NERSC, ACES (LANL/SNL), and the ALCF – the issue of performance portability is confronting the DOE mission like never before. A new best practice in the DOE is to include “Centers of Excellence” with each major procurement, with a goal of focusing efforts on preparing key applications to be ready for the systems coming to each site, and engaging the vendors directly in a “shared fate” approach to ensuring success. While each COE is necessarily focused on a particular deployment, applications almost invariably must be able to run effectively across the entire DOE HPC ecosystem. This tension between optimizing performance for a particular platform, while still being able to run with acceptable performance wherever the resources are available, is the crux of the challenge we call “performance portability”. This meeting was an opportunity to bring application developers, software providers, and vendors together to discuss this challenge and begin to chart a path forward.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2016

Optimizing the Costs of Solid Sorbent-Based CO 2 Capture Process Through Heat Integration

The focus of this project was the ADAsorb™ CO 2 Capture Process, a temperature-swing adsorption process that incorporates a three-stage fluidized bed as the adsorber and a single-stage fluidized bed as the regenerator. ADAsorb™ system was designed, fabricated, and tested under DOE award DEFE0004343. Two amine-based sorbents were evaluated in conjunction with the ADAsorb™ process: “BN”, an ion-exchange resin; and “OJ”, a metal organic framework (MOF) sorbent. Two cross heat exchanger designs were evaluated for use between the adsorber and regenerator: moving bed and fluidized bed. The fluidized bed approach was rejected fairly early in the project because the additional electrical load to power blowers or fans to overcome the pressure drop required for fluidization was estimated to be nominally three times the electrical power that could be generated from the steam saved through the use of the cross heat exchanger. The Energy Research Center at Lehigh University built and utilized a process model of the ADAsorb™ capture process and integrated this model into an existing model of a supercritical PC power plant. The Lehigh models verified that, for the ADAsorb™ system, the largest contributor to parasitic power was lost electrical generation, which was primarily electric power which the host plant could not generate due to the extraction of low pressure (LP) steam for sorbent heating, followed by power for the CO 2 compressor and the blower or fan power required to fluidize the adsorber and regenerator. Sorbent characteristics such as the impacts of moisture uptake, optimized adsorption and regeneration temperature, and sensitivity to changes in pressure were also included in the modeling study. Results indicate that sorbents which adsorb more than 1-2% moisture by weight are unlikely to be cost competitive unless they have an extremely high CO 2 working capacity that well exceeds 15% by weight. Modeling also revealed that reductions in adsorber pressure drop could negatively affect the CO 2 adsorption characteristics for sorbents with certain isobar adsorption characteristics like sorbent BN. Thus, reductions in pressure drop do not provide the efficiency benefits expected. A techno-economic assessment conducted during the project revealed that without heat integration, the a metal organic framework (MOF) sorbent used in conjunction with the ADAsorb™ process provided the opportunity for improved performance over the benchmark MEA process. While the addition of a cross heat exchanger and heat integration was found to significantly improve net unit heat rate, the additional equipment costs required to realize these improvements almost always outweighed the improvement in performance. The exception to this was for a supported amine sorbent and the addition of a moving bed cross heat exchanger alone or in conjunction with waste heat from the compressor used for supplemental regenerator heating. Perhaps one of the most important points to be drawn from the work conducted during this project is the significant influence of sorbent characteristics alone on the projected COE and LCOE associated with the ADAsorb™ process, and the implications associated with future improvements to solid sorbent CO 2 capture. The results from this project suggest that solid sorbent CO 2 capture will continue to see performance gains and lower system costs as further sorbent improvements are realized.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2017

CO 2 capture from IGCC gas streams using the AC-ABC process

The objective of this project was to develop a novel, low-cost CO 2 capture process from pre-combustion gas streams. The bench-scale work was conducted at the SRI International. A 0.15-MWe integrated pilot plant was constructed and operated for over 700 hours at the National Carbon Capture Center, Wilsonville, AL. The AC-ABC (ammonium carbonate-ammonium bicarbonate) process for capture of CO 2 and H 2 S from the pre-combustion gas stream offers many advantages over Selexol-based technology. The process relies on the simple chemistry of the NH 3 -CO 2 -H 2 O-H 2 S system and on the ability of the aqueous ammoniated solution to absorb CO 2 at near ambient temperatures and to release it as a high-purity, high-pressure gas at a moderately elevated regeneration temperature. It is estimated the increase in cost of electricity (COE) with the AC-ABC process will be ~ 30%, and the cost of CO 2 captured is projected to be less than $27/metric ton of CO 2 while meeting 90% CO 2 capture goal. The Bechtel Pressure Swing Claus (BPSC) is a complementary technology offered by Bechtel Hydrocarbon Technology Solutions, Inc. BPSC is a high-pressure, sub-dew-point Claus process that allows for nearly complete removal of H 2 S from a gas stream. It operates at gasifier pressures and moderate temperatures and does not affect CO 2 content. When coupled with AC-ABC, the combined technologies allow a nearly pure CO 2 stream to be captured at high pressure, something which Selexol and other solvent-based technologies cannot achieve.

08 HYDROGEN↗
DOE OSTI2017

Demonstration of Advanced CO 2 Capture Process Improvements for Coal-Fired Flue Gas

This document summarizes the activities of Cooperative Agreement DE-FE0026590, “Demonstration of Advanced CO 2 Capture Process Improvements for Coal-Fired Flue Gas” during the performance period of October 1, 2015 through May 31, 2017. This project was funded by the U.S. Department of Energy (DOE) National Energy Technology Laboratory (NETL). Southern Company Services, Inc. (SCS) was the prime contractor and co-funder of the project. Mitsubishi Heavy Industries America (MHIA) and AECOM were project team members. The overall project objective was to improve costs, energy requirements, and performance of an existing amine-based CO 2 capture process. This will occur via improvements in three areas: 1. Reboiler design – The first objective of the program was to demonstrate performance of an integrated stripper/reboiler (termed Built-in Reboiler, or BIR) to reduce footprint, capital costs, and integration issues of the current technology. 2. Particulate management – The second objective was to carry out a Particulate Matter Management (PMM) test. This has the potential to reduce operating costs and capital costs due to the reduced or eliminated need for mechanical filtration. 3. Solvent – The third objective was to carry out a new solvent test plan (referred to as NSL) to demonstrate a new solvent (termed New Solvent A), which is expected to reduce regeneration steam. The bulk price is also expected to be lower than KS-1, which is the current solvent used in this process. NSL testing would include baseline testing, optimization, long term testing, solvent reclamation testing, and final inspection. These combine to form the Advanced Carbon Capture (ACC) technology. Much of this work will be applicable to generic solvent processes, especially in regards to improved reboiler design, and focused to meet or exceed the DOE’s overall carbon capture performance goals of 90% CO 2 capture rate with 95% CO 2 purity at a cost of $40/tonne of CO 2 by 2025 and at a cost of electricity (COE) 30% less than baseline CO 2 capture approaches by 2030. This project was divided into two phases. Phase 1 is the planning phase, and Phase 2 is the construction, operations, testing, and analysis phase. A down select occurred after Phase 1. Phase 1 activities were carried out during this reporting period, and therefore, Phase 1 activities are solely considered in this report. The project was not selected for Phase 2 funding.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2017

Uncertainty Quantification of Multi-Phase Closures

In the ensemble-averaged dispersed phase formulation used for CFD of multiphase ows in nuclear reactor thermohydraulics, closures of interphase transfer of mass, momentum, and energy constitute, by far, the biggest source of error and uncertainty. Reliable estimators of this source of error and uncertainty are currently non-existent. Here, we report on how modern Validation and Uncertainty Quanti cation (VUQ) techniques can be leveraged to not only quantify such errors and uncertainties, but also to uncover (unintended) interactions between closures of di erent phenomena. As such this approach serves as a valuable aide in the research and development of multiphase closures. The joint modeling of lift, drag, wall lubrication, and turbulent dispersion|forces that lead to tranfer of momentum between the liquid and gas phases|is examined in the frame- work of validation of the adiabatic but turbulent experiments of Liu and Banko , 1993. An extensive calibration study is undertaken with a popular combination of closure relations and the popular k-ϵ turbulence model in a Bayesian framework. When a wide range of super cial liquid and gas velocities and void fractions is considered, it is found that this set of closures can be validated against the experimental data only by allowing large variations in the coe cients associated with the closures. We argue that such an extent of variation is a measure of uncertainty induced by the chosen set of closures. We also nd that while mean uid velocity and void fraction pro les are properly t, uctuating uid velocity may or may not be properly t. This aspect needs to be investigated further. The popular set of closures considered contains ad-hoc components and are undesirable from a predictive modeling point of view. Consequently, we next consider improvements that are being developed by the MIT group under CASL and which remove the ad-hoc elements. We use non-intrusive methodologies for sensitivity analysis and calibration (using Dakota) to study sensitivities of the CFD representation (STARCCM+) of uid velocity pro les and void fraction pro les in the context of Shaver and Podowski, 2015 correction to lift, and the Lubchenko et al., 2017 formulation of wall lubrication.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2018

Smart Matrix Development for Direct Carbonate Fuel Cell

FCE’s (FuelCell Energy, Inc.) SureSourceTM products based on high-temperature internal-reforming direct carbonate fuel cell (DFC®) technology are striving to meet growing worldwide demand for high-efficiency ultra-clean power for on-site electric and combined heat and power (CHP) generation. It promises ~20% higher energy conversion efficiency than existing technologies and its large-scale deployment would help to reduce GHG (Green House Gas) emission. In this program, FCE, teamed with University of Connecticut (UConn) and Illinois Institute of Technology (IIT), successfully developed an innovative electrolyte matrix (dubbed smart matrix since it promises higher power output, longer service life, and cost reduction gains concurrently) to enable the products to worldwide deployment. The electrolyte membrane (matrix) holds a very important key to fulfill these promises. The matrix, a porous microstructure consisting mainly of ultra-fine sub-micron α-LiAlO 2 powders sandwiched between two electrodes, immobilizes liquid electrolyte, isolates fuel from oxidant and facilitates ionic transport. However, faster coarsening of α-LiAlO 2 at the reducing anode side lowers capillary electrolyte-retention and eventually leads to matrix drying, limiting stack service life. This program, spanning over 3.5 years, successfully developed a high-yield cost-effective commercial-ready smart matrix with robust and stable fine-pore microstructure to enable the SureSource plants meeting DOE 2020 targets for CHP distributed generation fuel cell systems. Fundamental coarsening mechanism was established by investigating in detail the effects of electrolyte chemistry, powder morphology, powder purity, electrolyte chemistry, gas atmosphere and temperature. More stable powders with higher crystallinity, less surface disorder, less metastable impurities, less agglomeration and more uniform particle-size distribution have improved stability. FCE devised an innovative cost-effective additive approach to disrupt the fundamental coarsening process to enhance stability. The smart matrix design was validated in numerous long-term accelerated single cells and several 30kW technology stacks, many operated for >5,000 hours. Manufacturing process was successfully optimized to produce high-yield full-area (1 m 2 ) product-size smart matrices. Field deployment has been initiated. Successful development of this innovative smart matrix enables a quantum jump in useful life (100%) and power output (>20%). These improvements may project to >20% lower COE (Cost of Electricity) making the SureSource highly competitive with U.S. grid electricity cost leading to large-scale deployment, realizing the U.S. Government’s energy, environment, and economic agenda.

03 NATURAL GAS↗