Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “combustion processes”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Particle Matter Index and Fuel Wall-wetting Relations on Stochastic Pre-ignition

This works explores the effect of the particle matter index (PMI) and aromatic content on fuel wall impingement and associated stochastic pre-ignition (SPI) propensity. Statically significant measurements of SPI rates are directly coupled with laser induced florescence (LIF) measurements of fuel dilution from spray-linear impingement. Literature suggests that PMI is could be correlated with the number of SPI events, but the root cause(s) of PMI and SPI are directly causational or are a predicator of SPI. Three fuels have been used in this study with 3 different PMI and two different aromatic contents. These fuels are direct injected at two different injection timings, an earlier injection timing which targets the piston crown, 310°CA bTDC, and a later injection timing that the linear, 220°CA bTDC start of injection timings (SOI) respectively. The earlier 310 SOI injection increases soot, whereas the later 220°CD SOI targets the linear and increases wall-wetting. The findings of this work highlight that the SPI activity has a weak correlation with the soot promoted by the combustion process and increased PMI. However, SPI activity shows a strong dependency with high levels of oil dilution and aromatic content, suggesting that PMI might be an indicator of fuel chemistry conducive to SPI and the soot form increased PMI fuels is not a strong source of SPI relative to fuel wall wetting.

42 ENGINEERING↗
DOE OSTI2022

Simulations of Low Mach Number Reactive Flows Coupled with Electric Fields

Applying electric fields to flames can provide an effective, non-invasive control of the combustion process. In this work, an algorithm recently introduced to handle the interactions between reactive flows and an electric field is extended to handle multiple dimensions and adaptive mesh refinement (AMR), and applied to a series of laminar flames. Experimental data allows to validate the ability of the algorithm to capture the mechanisms driving the flame response to electric fields.

electric fields↗
DOE OSTI2022

Simulations of Low Mach Number Reactive Flows Coupled with Electric Fields: Preprint

Applying electric fields to flames can provide an effective, non-invasive control of the combustion process. In this work, an algorithm recently introduced to handle the interactions between reactive flows and an electric field is extended to handle multiple dimensions and adaptive mesh refinement (AMR), and applied to a series of laminar flames. Experimental data allows to validate the ability of the algorithm to capture the mechanisms driving the flame response to electric fields.

electric field↗
DOE OSTI2022

Industrial Load Flexibility, the U.S. Power Grid and Ammonia

A variable renewable power grid is a new technological regime that involves real time harvesting and low-cost availability of energy resources coupled with storage to meet additional needs. Decarbonization through electrification of end uses formerly met by combustion processes will be a concurrent trend. Taken together, these two changes may make flexibility on the demand side more valuable to the grid and to industrial users. Industry accounted for 26% of US power demand in 2021. Traditionally, industrial processes for producing ammonia and other basic materials have been optimized for a system based on fossil resources, where energy can be called upon according to needs. Large capital expenditures as well as safety considerations have favored plants running at steady state at close to their maximum capacity. It is possible, however, that the renewable energy transition will offer opportunities to sectors that can operate in a more flexible manner. Innovations that make use of flexibility to enhance their business model to move forward, individuals and groups active in their development, use and regulation, together with institutions and infrastructures, can be considered as a technological innovation system (TIS). Beyond economic and technical factors on their own, the TIS is an important analysis framework for studying the development and diffusion of technologies. This work attempts to map the TIS of flexible industrial loads and their interaction with electric power in the US, with a particular focus on ammonia as a case study. We have conducted interviews with stakeholders involved in ammonia projects, working in system operators, trade groups, regulators and utilities. We assess to what extent a technological innovation system is functioning and document characteristics that allow industries to operate flexibly.

ammonia↗
DOE OSTI2025

Approach for High Methanol Substitution by Energy with Conventional and Bio Pilot Fuels

Green methanol is emerging as a promising route to decarbonize the commercial marine industry. However, methanol is not a drop-in fuel in the compression ignition engines that dominate the marine industry because it is difficult to ignite due to its low cetane number and high latent heat of vaporization. The most straight-forward way to use methanol in the compression ignition engines is to premix the methanol, such as with port fuel injection during the intake stroke, and igniting the methanol with a diesel pilot injection. Because diesel fuel is still used in this strategy, it does not fully displace the petroleum diesel fuel. To completely displace the petroleum-derived diesel fuel, this investigation presents experimental results comparing diesel and biodiesel pilot ignition in a dual-fuel strategy with methanol in a marine-variant of a Cat® C18 18 L engine with a 145 mm bore. Engine performance and emissions characteristics are presented that include effects of diesel vs. biodiesel across a series of fuel injection timing and other operating parameters, including intake manifold pressure and engine load. Results presented include in-cylinder pressure and combustion-related findings about heat release, methanol fuel energy substitution rates greater than 75% from 1 to 18 bar BMEP on a single cylinder engine at 1800 RPM. Criteria pollutants including particulate matter, NOx (NO and NO2), unburned fuel, and formaldehyde, as well as the overall BSFC and FSN of the combustion process relative to the baseline diesel operation.

Splitter, Derek [ORNL] (ORCID:0000000174044047)↗
DOE OSTI2025

FLEX-FUEL MIXING CONTROLLED COMBUSTION ENABLED BY PRECHAMBER IGNITION

There is an imminent need to displace fossil diesel fuel with cleaner burning, domestically produced, renewable fuels for use in heavy-duty engines. Bioethanol is a prime candidate as it widely adopted in the U.S. as a gasoline additive ranging in volume percentage from 10% (E10) up to 85% (E85). Direct substitution of market available ethanol-gasoline blends for diesel fuel is not plausible as the stark reactivity differences would not constitute the same ignition quality nor achieve auto-ignition at all. This work focuses on the development of prechamber enabled mixing-controlled combustion (PC-MCC) as an advanced combustion strategy to facilitate reliable ignition and diffusion style combustion ethanol-gasoline fuel blends. PC-MCC involves integration of an actively fueled prechamber (PC) into a conventional compression ignition combustion system. When ignited, the PC ejects hot turbulent jets into the main combustion chamber that then interact with the direct injected fuel, prompting immediate ignition. The PC jet flames provide a robust thermal ignition source that allows the engine to operate agnostic of fuel composition, or flex-fuel. Computational fluid dynamics (CFD) modeling was used to assess critical design features of the PC while garnering insights into the ignition strategies that facilitate robust performance. A key finding was the ignition performance benefits of fuel-rich PC operation which yield exothermic jets. Based on the numerical findings, a prototype igniter was tested experimentally on both single and multi-cylinder engine platforms at a variety of operating conditions. The experimental results indicate flex-fuel PC-MCC is well capable of diesel-like combustion processes by demonstrating matched or improved gross thermal efficiencies and load variability within 2%. Fuel grade ethanol (E98) exhibited consistently lower NOx and immeasurable soot across the load space. E98 also demonstrated a significant improvement in thermal efficiency at light loads.

Zeman, Jared↗
DOE OSTI2022

Integrated Water-Gas-Shift Pre-combustion Carbon Capture Process

TDA Research, Inc (TDA) has developed a highly efficient integrated WGS pre-combustion carbon capture technology and demonstrated its techno-economic viability for use in the Integrated Gasification Combined Cycle (IGCC) power plants that process coal. The new system uses a warm gas CO 2 scrubber integrated with a Water-Gas-Shift (WGS) catalyst to capture greater than 90% of the carbon emissions, which does not increase the cost of electricity (COE) as much as conventional carbon capture technologies.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

Chapter 11: Biochar Production

In production of biochar, thermochemical processes that can be used to treat biomass include pyrolysis, gasification, hydrothermal processing, and combustion. Each of these processes is defined by specific operating conditions (e.g., temperature, presence of oxygen) and feedstock requirements for optimal conversion to the product of primary interest. Each process results in varying fractions of gaseous, liquid, and solid products. Though other publications have emphasized the gaseous bio-energy products of such processes (e.g., bio-oil, synthesis gas or "syngas") with biochar as a co-product, in this discussion, we focus primarily on biochar as the In production of biochar, thermochemical processes that can be used to treat biomass include pyrolysis, gasification, hydrothermal processing, and combustion. Each of these processes is defined by specific operating conditions (e.g., temperature, presence of oxygen) and feedstock requirements for optimal conversion to the product of primary interest. Each process results in varying fractions of gaseous, liquid, and solid products. Though other publications have emphasized the gaseous bio-energy products of such processes (e.g., bio-oil, synthesis gas or "syngas") with biochar as a co-product, in this discussion, we focus primarily on biochar as the main product, with heat and electrical energy as co-products of secondary interest. The reasons for this are as follows: when producing biochar, heat is the simplest form of energy to capture and utilize, electrical energy can be generated from heat energy with a wide range of available technologies small and large; rather than immediately combusting the gases released from biomass, there is potential to refine the gases into bio-oil and syngas. However, much larger investments of capital are needed to build facilities for which gaseous fuel production is the primary goal, as compared to those focused on biochar production with heat and electrical energy co-products. While the economic viability of biochar production will be improved by production of high-value co-products (e.g., wood acids for use in pesticides), the simplest production scheme is one in which biochar and heat are the primary products. Here we aim to provide a broader overview of thermochemical processes and technologies most relevant to biochar production in its current state of commercialization. All biochar is a result of pyrolysis (the reaction) but not all biochar is made with a dedicated pyrolysis reactor (the technology type). Further, all biochar is the result of a lack of complete combustion (the reaction), even biochar produced in a combustion or gasification reactor (the technology type). This is an important distinction to acknowledge in the following sections in which we discuss both thermochemical conversion reactions and technology types.

biochar↗
DOE OSTI2025

Climate, air quality, and equity benefits from hydrogen substitution for fossil fuels used in process heat

Fossil fuel combustion for process heat in heavy industry accounts for ~15% of all United States CO 2 emissions and emits PM 2.5 and its precursors, emissions that have a disproportionate impact on minority populations. Decarbonizing process heat in the U.S. via hydrogen substitution presents an opportunity to reduce emissions of CO 2 and PM 2.5 and mitigate resulting exposure disparity. Here, we show that hydrogen substitution in steelmaking provides a large reduction in CO 2 emissions and air quality-related premature mortality, while hydrogen substitution in petroleum refining substantially benefits disadvantaged communities. When reductions in CO 2 emissions and premature mortality are monetized using standard regulatory values, we find that the sum of air pollution and climate benefits outweighs the difference in private cost associated with hydrogen substitution in steelmaking, regardless of the method of hydrogen production. The approach developed here can support evaluations of equity-focused decarbonization strategies in other industries and for specific sites.

08 HYDROGEN↗
DOE OSTI2021

A systematic comparison of machine learning methods for modeling of dynamic processes applied to combustion emission rate modeling

Ten established, data-driven dynamic algorithms are surveyed and a practical guide for understanding these methods generated. Existing Python programming packages for implementing each algorithm are acknowledged, and the model equations necessary for prediction are presented. A case study on a coal-fired power plant’s NO x emission rates is performed, directly comparing each modeling method’s performance on a mutual system. Each model is evaluated by its root mean squared error (RMSE) on out-of-sample future horizon predictions. Optimal hyperparameters are identified using either an exhaustive search or genetic algorithm. The top five model structures of each method are used to recursively predict future NO x emission rates over a 60-step time horizon. The RMSE at each future timestep is determined, and the recursive output prediction trends compared against measurements in time. The GRU neural network is identified as the best candidate for representing the system, demonstrating accurate and stable predictions across the future horizon by all considered models, while satisfactory performance was observed in several of the ARX/NARX formulations. Finally, these efforts have contributed 1) a concise resource of multiple proven dynamic machine learning methods, 2) a practical guide explaining the use of these methods, effectively lowering the “barrier-to-entry” of deploying such models in control systems, 3) a comparison study evaluating each method’s performance on a mutual system, 4) demonstration of accurate multi-timestep emissions modeling suitable for systems-level control, and 5) generalizable results demonstrating the suitability of each method for prediction over a multi-step future horizon to other complex dynamic systems.

42 ENGINEERING↗
DOE OSTI2026

Designing a Robust MEA-Based Post-Combustion Carbon Capture Process with Capture Rate Guarantees

This work presents an application of the nonlinear two-stage robust optimization solver PyROS to the model-based design and operation of a monoethanolamine scrubbing process for CO<sub>2</sub> capture under epistemic uncertainty. Through this application, risk-averse process designs are successfully obtained for CO<sub>2</sub> capture targets ranging from 90% to over 99%. In particular, the risk-averse solutions for CO<sub>2</sub> capture targets of up to 98% are shown to be only marginally more expensive than their nominally optimal counterparts. Thus, the results demonstrate the utility of recently developed nonlinear robust optimization approaches for the solution of large-scale chemical process models under uncertainty.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2025

Plasma Assisted Combustion and Chemical Processing: Chapter 9 - Plasma Diagnostics

Plasma dynamics and chemistry have a broad range of timescales from picoseconds to milliseconds. In addition, it involves nonequilibrium energy transfer between electrons, ions, electronically and vibrationally excited states, radicals, intermediate species, and reactants and products as well as surface charges and chemistry. To understand plasma physics and chemistry, it is essential to conduct time and space resolved, quantitative detection of nonequilibrium temperature distributions, electron energy and number density, electric field, and species concentrations. There are enormous publications and review articles on this subject. The focus of this chapter is to be placed on the most recent progress in gas phase plasma properties and chemistry, especially on optical emission spectroscopy, laser absorption spectroscopy, Faraday rotational spectroscopy, Raman and Thompson scattering, femtosecond and picosecond (fs/ps) coherent anti-Stokes Raman scattering (CARS) spectroscopy, and electric field-induced second harmonic generation methods.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Pilot Test of a Nanoporous, Super-hydrophobic Membrane Contactor Process for Post-combustion CO 2 Capture

GTI Energy and Air Liquide Advanced Separations (ALaS) have been developing a novel hollow fiber membrane contactor (HFMC) technology for post-combustion CO 2 capture. The process combines advantageous features of both absorption and membrane-based separation processes to separate CO 2 from flue gas cost-effectively. The key component of the HFMC technology is the super-hydrophobic, porous hollow fiber, which is made from polyether ether ketone (PEEK). Compared to conventional absorption/desorption technologies, the critical advantage of the HFMC process is the high contact surface area provided by the hollow fibers enabling an increased volumetric mass-transfer rate. In the PEEK HFMC process, the specific surface area has been increased by an order of magnitude over structurally packed or trayed columns, resulting in compact systems with small footprints.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2022

TEA of a Unique Two-Pathways Process for Post-Combustion CO 2 Capture

A unique two-Pathways process using aqueous sodium glycinate for CO 2 capture from a split flue gas stream emitted from 600 MWe post-combustion coal power plant was developed in Aspen Plus v.10. The split gas flow rate used was 44.75 ton/h and contained 0.0023 mol% SO 2 and 13.33 mol% CO 2 . The process includes a washing unit, a CO 2 absorption unit, a reverse osmosis unit, and a solvent regeneration unit or an ultrafiltration unit. The washing unit uses deionized water to completely remove SO 2 and the CO 2 absorption unit uses SGS to capture at least 90 mol% of the CO 2 in the split flue gas stream. Upon CO 2 and SGS reactions, the resulting liquid products exhibit phase-separation into CO 2 -lean phase and CO 2 -rich phase, allow two distinct pathways. Pathway (i) is to regenerate mostly the CO 2 -rich phase, collect the released CO 2 , and compress it for sequestration purposes. Pathway (ii) is to send the liquid stream from the CO 2 absorption unit to the ultrafiltration unit to separate the solid nanomaterials. The hydraulics and mass transfer characteristics in the washing and CO 2 absorption units were obtained; and techno-economic analysis (TEA) for Pathways (i) and (ii), including Capital Expenditure (CAPEX), Operating Expenditure (OPEX), and Levelized Cost of CO 2 Captured (LCOC), were calculated and compared. The simulation results revealed that the CAPEX, OPEX, and LCOC for Pathway (i) were ($\$12,039,251$), (261 dollar/h), and (54.01 dollar/ton-CO 2 captured), respectively, and those for Pathway (ii) were ($\$5,908,000$), (237.2 dollar/h), and (39.90 dollar/ton-CO 2 captured), respectively. Moreover, in Pathway (ii), 8.19 ton/h of CO 2 were captured to produce 15.62 ton/h NaHCO 3 nanomaterials, which were sold to offset the overall process cost. The LCOC values indicate that Pathway (ii) is more cost-effective than Pathway (i) because LCOC values for Pathway (ii) are much lower than those for Pathway (i).COC values for Pathway (ii) are much lower than those for Pathway (i).

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2022

Parametric Testing and Evaluation of a Novel Biphasic Absorption Process for Post-Combustion Carbon Capture

A novel biphasic CO2 absorption process (BiCAP) is being developed at the University of Illinois. BiCAP is enabled by using a new class of biphasic solvents developed based on multi-property criteria for postcombustion carbon capture. The process was previously demonstrated at the lab-scale, including in 10 kWe absorption and desorption column systems. In the current study, the process has been scaled up by building and testing a 40 kWe integrated capture skid at a power plant. Parametric tests for two biphasic solvents were conducted with the synthetic flue gas made of bottle CO2 gas and air to validate the performance and operational flexibility of the unit with respect to varying process or operating conditions. Operation of the phase separator, which is unique equipment to BiCAP, was verified to be stable and efficient. Two liquid phases could be separated via static settlement based on a density difference and >90% of the CO2 absorbed was concentrated in the separated CO2-rich phase. Results of parametric tests showed that the minimum heat duty appeared at the optimal stripping pressure. A higher stripping temperature was more favourable to improve overall energy performance. Introducing a secondary cold solvent feed stream to the top of the stripper via bypassing the cross heat exchanger helped reduce the heat loss carried with water vapour. Test results also revealed that the heat duty requirement was comparable when the CO2 concentration in flue gas decreased from ~11 to 4 vol.% as the phase separation decoupled the absorption and desorption steps in BiCAP. Under typical steady-state conditions, both biphasic solvents lowered the process heat duty by >40% compared with the reference 30 wt.% monoethanolamine solvent.

Absorption↗
DOE OSTI2022

Additively manufactured metal energetic ligand precursors and combustion synthesis

Processes for tailoring the macroscopic shape, metallic composition, mechanical properties, and pore structure of nanoporous metal foams prepared through combustion synthesis via direct write 3D printing of metal energetic ligand precursor inks made with water and an organic thickening agent are disclosed. Such processes enable production of never before obtainable metal structures with hierarchical porosity, tailorable from the millimeter size regime to the nanometer size regime. Structures produced by these processes have numerous applications including, but not limited to, catalysts, heat exchangers, low density structural materials, biomedical implants, hydrogen storage medium, fuel cells, and batteries.

Tappan, Bryce↗
DOE OSTI2021

CFD/FEA Co-Simulation Framework for Analysis of the Thermal Barrier Coating Design and Its Impact on the HD Diesel Engine Performance

Thermal barrier coatings (TBCs) have been investigated both experimentally and through simulation for mixing controlled combustion (MCC) concepts as a method for reducing heat transfer losses and increasing cycle efficiency, but it is still a very active research area. Early studies were inconclusive, with different groups discovering obstacles to realizing the theoretical potential. Nuanced papers have shown that coating material properties, thickness, microstructure, and surface morphology/roughness all can impact the efficacy of the thermal barrier coating and must be accounted for. Adding to the complexities, a strong spatial and temporal heat flux inhomogeneity exists for mixing controlled combustion (diesel) imposed onto the surfaces from the impinging flame jets. In support of the United States Department of Energy SuperTruck II program goal to achieve 55% brake thermal efficiency on a heavy-duty diesel engines, this study sought to develop a deeper insight into the inhomogeneous heat flux from mixing controlled combustion on thermal barrier coatings and to infer concrete guidance for designing coatings. To that end, a co-simulation approach was developed that couples high-fidelity computational fluid dynamics (CFD) modeling of in-cylinder processes and combustion, and finite element analysis (FEA) modeling of the thermal barrier-coated and metal engine components to resolve spatial and temporal thermal boundary conditions. The models interface at the surface of the combustion chamber; FEA modeling predicts the spatially resolved surface temperature profile, while CFD develops insights into the effect of the thermal barrier coating on the combustion process and the boundary conditions on the gas side. The paper demonstrates the capability of the framework to estimate cycle impacts of the temperature swing at the surface, as well as identify critical locations on the piston/thermal barrier coating that exhibit the highest charge temperature and highest heat fluxes. In addition, the FEA results include predictions of thermal stresses, thus enabling insight into factors affecting coating durability. An example of the capability of the framework is provided to illustrate its use for investigating novel coatings and provide deeper insights to guide future coating design.

42 ENGINEERING↗