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DOE OSTI2021

Technology Assessment on Low-Temperature Waste Heat Recovery in Industry

The purpose of this report is to discuss the magnitude of low-temperature waste heat available in the US manufacturing sector and to identify current and emerging low-temperature heat recovery technologies and equipment. The primary focus of the study is on the industries that produce the lowest-temperature waste heat: the chemical, primary metal, petroleum, nonmetallic mineral, fabricated metal, food, paper, and wood industries. In addition to identifying the waste streams, their characteristics, and currently available heat recovery technologies, the study also explored future research opportunities and economic barriers for recovery technology implementation. Special attention was given to applicable heat to power conversion technologies such as the organic Rankine cycle, thermoelectric conversion, and the supercritical CO 2 cycle. The study included investigations in research and new developments, including turbine and heat exchanger cost for waste heat to power systems, size, efficiency, and intermittency of waste heat streams.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2021

Modeling Molten Salt Spreading and Heat Transfer using MELTSPREAD – An Uncertainty Analysis

This report summarizes spreading and heat transfer results for molten salt pouring onto a flat stainless steel substrate that were calculated using MELTSPREAD to gain insight into bulk salt behavior during a molten salt spill accident. MELTSPREAD was developed at Argonne to model the one-dimensional flow and freezing behavior of molten corium and is being applied to model molten salts for the first time as part of this work. An uncertainty analysis of thermophysical properties and spill conditions was performed using MELTSPREAD to determine which properties and conditions have the greatest impact on model outcome. The model was run with and without the inclusion of decay heat. Eutectic FLiNaK was used as the salt composition because it is well-characterized and appropriate for model development. Small salt volumes were used for the initial model runs described in this report so that the model results can be compared to the results from ongoing experiments on molten salt spreading and heat transfer currently being conducted at Argonne at a benchtop scale. The spreading of a small volume of FLiNaK (50 mL) was found to be limited by the balance between the molten salt surface tension and gravity and not by freezing for the pour conditions and assumed mechanisms of heat transfer in the model. Heat transfer from the salt was highly inefficient to due to its low thermal conductivity, high heat capacity, and high heat of fusion and varying these properties had no effect on the spreading behavior. Changing the viscosity and density of the salt slightly affected the spreading behavior. Setting the salt surface tension to approximately zero to simulate the salt wetting the substrate had the greatest effect on the spreading behavior and this increased both the spreading velocity and overall spreading area. Including decay heat in the model had a significant effect on the long-term cooling behavior of the salt but had no effect on the overall spreading behavior. Future effort should involve modeling a larger volume of molten salt to represent a reactor case spill scenario because the spreading behavior of large volumes of salt may differ from the small volumes that were the focus of this document.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2023

End-Use Savings Shapes Measure Documentation: Variable Refrigerant Flow with Heat Recovery and Dedicated Outdoor Air System

Building on the successfully completed effort to calibrate and validate the U.S. Department of Energy's ResStock™ and ComStock™ models over the past 3 years, the objective of this work is to produce national data sets that empower analysts working for federal, state, utility, city, and manufacturer stakeholders to answer a broad range of analysis questions. The goal of this work is to develop energy efficiency, electrification, and demand flexibility end-use load shapes (electricity, gas, propane, or fuel oil) that cover a majority of the high-impact, market-ready (or nearly market-ready) measures. "Measures" refers to energy efficiency variables that can be applied to buildings during modeling. An end-use savings shape is the difference in energy consumption between a baseline building and a building with an energy efficiency, electrification, or demand flexibility measure applied. It results in a time-series profile that is broken down by end use and fuel (electricity or on-site gas, propane, or fuel oil use) at each time step. ComStock is a highly granular, bottom-up model that uses multiple data sources, statistical sampling methods, and advanced building energy simulations to estimate the annual subhourly energy consumption of the commercial building stock across the United States. The baseline model intends to represent the U.S. commercial building stock as it existed in 2018. The methodology and results of the baseline model are discussed in the final technical report of the End-Use Load Profiles project. This documentation focuses on a single heating, ventilation, and air-conditioning (HVAC) end-use savings shape measure - a variable refrigerant flow with heat recovery (VRF HR) heating and cooling system coupled with a dedicated outdoor air system (DOAS) for ventilation. This measure replaces existing multi-zone variable air volume (VAV) systems or single-zone rooftop units (RTU) with a VRF HR system coupled with a DOAS that includes an energy/heat recovery ventilator (E/HRV). The measure covers 53% of exisiting building stock's floor area and is not applicable to HVAC system types using district heating or cooling or buildings/spaces that include high-ventilation spaces such as kitchens where the amount of exhaust air is large. A DOAS with E/HRV is used to provide required outdoor ventilation air to spaces since ventilation air is generally not supplied by a VRF HR system. An exhaust air energy recovery ventilator (ERV ) with sensible and latent heat exchange is added to humid climate zones while a heat recovery ventilator (HRV ) with sensible only exchange is added to drier climate zones. The ERV is modeled as a fixed membrane plate counterflow heat exchanger, while the HRV is modeled as a sensible-only fixed aluminum plate counterflow heat exchanger. Both systems include a bypass (for temperature control and economizer lockout) and minimum exhaust temperature control for frost prevention.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

ORNL Campus Sustainability and Decarbonization using Waste Heat Recovery from the Oak Ridge Leadership Computing Facility’s High-Performance Computing Data Center

Heat pumps are a clean and efficient technology that can be powered by renewable electricity to transfer heat using a refrigerant from one place to another by different heat sources, making buildings clean and environmentally friendly. With the support of the ORNL Laboratory Modernization Division, this project explored and evaluated an innovative solution that uses water-water cost-effective midtemperature heat pump (MTHP) technology to leverage the low-grade waste heat from ORNL Frontier and the data center to deliver 85°C hot water, which replaces hot steam generated using natural gas combustion boilers for water heating or space heating in the buildings of ORNL campus. Two scenarios were studied. In the first scenario, which considered the 5600-5700-5800 complex only, Carrier’s commercial 1,000 kW MTHP technology achieves more than 6,640 MWh/year energy savings, an emission reduction of 858 TCO2e/year CO2, and a payback time of 4.85 years. In the second scenario, which considered the 5600-5700-5800 complex and Buildings 5100, 5200, and 5300, the CO2 emission reduction is 1,483 TCO2e/year, the operating cost savings are $0.21 million annually, and the payback time is 3.74 years. Additionally, a comprehensive HP ShowCase Tool was developed for evaluating the optimal solution to improve sustainability and decarbonization of the buildings on the ORNL campus. The tool is an Excel-based tool integrated with VBA (Visual Basic for Applications) coding. The tool includes collected ORNL campus building information and an MTHP library, which comprises collected commercial and ORNL-defined MTHPs. The tool was used to evaluate the sustainability and decarbonization of the ORNL campus. The tool can be widely used or referenced for heat pump solutions and building decarbonization renovation strategies to modernize ORNL facilities and energy use–intensive equipment to enable efficient, sustainable, and resilient operations in the future.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2024

Radioisotope Power System Cask Trailer Chiller Low Heat Load Study

This report documents the study of the Radioisotope Thermoelectric Generator Transport System (RTGTS) chillers capability to transport a Radioisotope Power System (RPS) with low heat loads in the cask. Tests of the RTGTS chillers included setting the glycol/water (coolant) temperature to a control set point of 40° and 60°F while applying heat loads ranging from 2500 to 0 W heat load. The tests performed showed that the chiller systems could handle the entire range of heat loads. However, a noise/vibration started to occur when the set point was 60°F with low heat loads. Three recommended changes to the RTGTS chillers are recommended with varying implementation windows. The first is an operational change that can be implemented immediately. The RTGTS chillers should have a set point of 40°F when transporting an RPS less than 1500 W. The second is a short-term change (within the next two years) augmenting RPS heat by utilizing one RTGTS onboard heater (2500 W) while transporting an RPS with less than 1500 W which will also require a change to the Instrument and Data Acquisition System (IDAS) to allow monitoring and possible control of power to the onboard heaters. However, if the heater does fail during transport, no emergency actions or immediate repairs will be required due to the chillers’ ability to handle low heat loads. Running a 2500 W heater when transporting low heat loads aids in prolonging the life of the chillers. The remaining recommended long-term change is to replace the current chillers with a new portable or permanently installed chiller system in the next five to ten years. This time frame takes advantage of the proven reliability and durability of the current chillers while the new chillers are phased in and proven to the RPS program.

42 ENGINEERING↗

DOE OSTI2025

Performance Results from DOE Cold Climate Heat Pump Challenge Field Validation

Space conditioning and water heating consume over 40% of the nation’s primary energy use and represent a significant component of many homeowners’ monthly energy bill. However, in cold climates, performance of heat pumps has traditionally suffered as the units have been unable to efficiently transfer heat from colder outdoor air temperatures to warm the interior space of homes. Optimizing heat pumps for cold climates (5 °F and below) requires coordinated effort to ensure heat pump technologies can be enjoyed by Americans living in these regions. The DOE Cold Climate Heat Pump (CCHP) Challenge sought to address this challenge by partnering with industry to develop, test, and validate the performance of new, highly efficient heat pumps in real homes. The Challenge, launched in 2021, brought together leading heating, ventilation, and air conditioning (HVAC) manufacturers to develop prototype units optimized for performance at cold climates. This report summarizes results from the field validation that occurred 2022-2024.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

Improvements to Passive Heat Removal Systems in SAS4A/SASSYS-1

Safe operation of a sodium cooled fast reactor (SFR) can be significantly aided by heat removal systems that do not rely on active power, but function using passive means. Passive heat removal from such reactors can employ systems that extract heat directly from sodium coolant by utilizing heat exchangers submerged in the coolant and natural circulation of a metal fluid sodium (or sodium potassium eutectic) to heat exchangers (generally air cooled) externally located. These types of systems are generally called Direct Reactor Auxiliary Cooling Systems (DRACS). Another type of passive heat removal system particularly suitable for pool-type SFRs relies on indirect extraction of heat by utilizing air flow in an annular region surrounding the reactor guard vessel which discharges the heat via the chimney effects to the atmosphere. These systems are generally called Reactor Vessel Auxiliary Cooling Systems (RVACS).

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2021

Environmental and Economic Assessment of Portable Systems: Production of Wood-Briquettes and Torrefied-Briquettes to Generate Heat and Electricity

This study assessed the environmental impacts and economic feasibility of generating heat using wood-briquettes (WBs), and heat and electricity using torrefied-wood-briquettes (TWBs). WBs and TWBs were manufactured from forest residues using portable systems and delivered to either residential consumers or power plants in the United States. An integrated cradle-to-grave life-cycle assessment (LCA) and techno-economic analysis (TEA) approach was used to quantify environmental impacts and minimum-selling prices (MSPs) of heat and electricity, respectively. Results illustrated that 82% and 59% of the cradle-to-grave global warming (GW) impact of producing heat resulted from the feedstock preparation in WBs and torrefaction in TWBs, respectively. About 46–54% of total cost in the production of heat were from labor and capital costs only. The GW impact of electricity production with TWBs was dominated by the torrefaction process (48% contribution). Capital cost (50%) was a major contributor to the total cost of electricity production using TWBs. The GW impacts of producing heat were 7–37 gCO₂eq/MJ for WBs, and 14–51 gCO₂eq/MJ for TWBs, whereas producing electricity using TWBs was 146–443 gCO₂eq/kWhe. MSPs of generating heat from WBs and TWBs were €1.09–€1.73 and €1.60–€2.26/MJ, respectively, whereas the MSP of electricity from TWBs was €20–€25/kWhe. Considering carbon and pile-burn credits, MSPs of heat and electricity were reduced by 60–90% compared to the base-case.

Sahoo, Kamalakanta (ORCID:0000000277635296)↗

DOE OSTI2025

Extreme Heating of Minor Ions in Imbalanced Solar-wind Turbulence

Minor ions in the solar corona are heated to extreme temperatures, far in excess of those of the electrons and protons that comprise the bulk of the plasma. These highly nonthermal distributions make minor ions sensitive probes of the collisionless processes that heat the corona and power the solar wind. The recent discovery of the "helicity barrier" offers a mechanism in which imbalanced Alfvénic turbulence in low-β plasmas preferentially heats protons over electrons, generating high-frequency, proton-cyclotron-resonant fluctuations. We use the hybrid-kinetic particle-in-cell code Pegasus++ to drive imbalanced Alfvénic turbulence in a 3D low-β plasma with additional passive ion species, He 2+ and O 5+ . A helicity barrier naturally develops, followed by clear phase-space signatures of oblique proton-cyclotron-wave heating and Landau-resonant heating from the imbalanced Alfvénic fluctuations. The former results in characteristically arced ion velocity distribution functions, whose non-bi-Maxwellian features are shown by linear ALPS calculations to be critical to the heating process. Additional features include a steep transition-range electromagnetic spectrum, proton-cyclotron waves propagating in the direction of the imbalance, significantly enhanced proton-to-electron heating ratios, ion temperatures that are considerably more perpendicular with respect to magnetic field, and extreme heating of heavier species in a manner consistent with mass scalings inferred from spacecraft measurements. None of these features are realized in an otherwise equivalent simulation of balanced turbulence. If seen simultaneously in the fast solar wind, these signatures of the helicity barrier would testify to the necessity of incorporating turbulence imbalance in a complete theory for the evolution of the solar wind.

79 ASTRONOMY AND ASTROPHYSICS↗

DOE OSTI2022

Rapid attribution analysis of the extraordinary heat wave on the Pacific coast of the US and Canada in June 2021

Towards the end of June 2021, temperature records were broken by several degrees Celsius in several cities in the Pacific Northwest areas of the US and Canada, leading to spikes in sudden deaths and sharp increases in emergency calls and hospital visits for heat-related illnesses. Here we present a multi-model, multi-method attribution analysis to investigate the extent to which human-induced climate change has influenced the probability and intensity of extreme heat waves in this region. Based on observations, modelling and a classical statistical approach, the occurrence of a heat wave defined as the maximum daily temperature (TXx) observed in the area 45–52 °N, 119–123 °W, was found to be virtually impossible without human-caused climate change. The observed temperatures were so extreme that they lay far outside the range of historical temperature observations. This makes it hard to state with confidence how rare the event was. Using a statistical analysis that assumes that the heat wave is part of the same distribution as previous heat waves in this region led to a first-order estimation of the event frequency of the order of once in 1000 years under current climate conditions. Using this assumption and combining the results from the analysis of climate models and weather observations, we found that such a heat wave event would be at least 150 times less common without human-induced climate change. Also, this heat wave was about 2 °C hotter than a 1-in-1000-year heat wave would have been in 1850–1900, when global mean temperatures were 1.2 °C cooler than today. Looking into the future, in a world with 2 °C of global warming (0.8 °C warmer than today), a 1000-year event would be another degree hotter. Our results provide a strong warning: our rapidly warming climate is bringing us into uncharted territory with significant consequences for health, well-being and livelihoods. Adaptation and mitigation are urgently needed to prepare societies for a very different future.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

A multi-scale time-series dataset of anthropogenic heat from buildings in Los Angeles County

The dataset contains hourly Anthropogenic heat (AH) from buildings in Los Angeles County, based on weather data from 2018. The hourly AH is aggregated at three spatial resolutions: 450m x 450m grid, 12km x 12km grid, and census tract. The AH is broken down into three components: building envelope surface convection, heating, ventilation, and air conditioning (HVAC) system heat release, and zone exfiltration and exhaust air heat loss. The dataset is created with the physics-based EnergyPlus building energy models to calculate individual buildings' AH considering WRF-UCM simulated microclimate conditions. Please refer to the paper "A multi-scale time-series dataset of anthropogenic heat from buildings in Los Angeles County" for more information about the data generation workflow and the data validation procedure. The data set contains two folders: the "output_data" folder holds the simulation results (EP_output and EP_output_csv), building metadata (building_metadata.geojson and building_metadata.csv), aggregated heat emission and energy consumption time-series data (hourly_heat_energy), and geographical data (geo_data) associated with the GEOID referenced in heat and energy consumption data. The "input_data" folder contains the raw data used to generate files in the "output_data" folder as well as data sets used in the validation. The code repository (https://github.com/IMMM-SFA/xu_etal_2022_sdata) holds the processing scripts for data curation, validation, and visualization.

Energy↗

NASA NTRS1971

Mathematical modeling of high and low temperature heat pipes

Following a review of heat and mass transfer theory relevant to heat pipe performance, math models are developed for calculating heat-transfer limitations of high-temperature heat pipes and heat-transfer limitations and temperature gradient of low temperature heat pipes. Calculated results are compared with the available experimental data from various sources to increase confidence in the present math models. Complete listings of two computer programs for high- and low-temperature heat pipes respectively are included. These programs enable the performance to be predicted of heat pipes with wrapped-screen, rectangular-groove, or screen-covered rectangular-groove wick.

Chi, S. W.↗

NASA NTRS1971

Test of 50-kw heat-pipe radiator.

A heat pipe radiator consisting of 100 sodium-filled, 1.91-cm OD, stainless steel heat pipes has been tested at temperatures up to 760 C. This radiator was initially designed to have a heat pipe temperature of 740 C with a central coolant channel temperature of 771 C. The as-fabricated radiator heat pipe temperatures varied from 605 C to 700 C when the central coolant channel average temperature was 740 C. The heat pipes operated at 25 C to 110 C lower-than-expected temperatures, resulting in a 43 kW heat rejection capability vs the 50 kW design goal and the 65 kW ultimate capability of the radiator. The 43 kW heat rejection yields a mass/heat rejection ratio of 0.182 kg/kWt which is good for this early state-of-the-art heat pipe radiator. An end-of-mission life specific weight of 0.154 kg/kW is apparently achievable with improvements in radiator fabrication and brazing techniques.

Kikin, G. M.↗

NASA NTRS1973

Heat pipe radiator

A 15,000 watt spacecraft waste heat rejection system utilizing heat pipe radiator panels was investigated. Of the several concepts initially identified, a series system was selected for more in-depth analysis. As a demonstration of system feasibility, a nominal 500 watt radiator panel was designed, built and tested. The panel, which is a module of the 15,000 watt system, consists of a variable conductance heat pipe (VCHP) header, and six isothermalizer heat pipes attached to a radiating fin. The thermal load to the VCHP is supplied by a Freon-21 liquid loop via an integral heat exchanger. Descriptions of the results of the system studies and details of the radiator design are included along with the test results for both the heat pipe components and the assembled radiator panel. These results support the feasibility of using heat pipes in a spacecraft waste heat rejection system.

Swerdling, B.↗

NASA NTRS1973

Space shuttle heat pipe thermal control systems

Heat pipe (HP) thermal control systems designed for possible space shuttle applications were built and tested under this program. They are: (1) a HP augmented cold rail, (2) a HP/phase change material (PCM) modular heat sink and (3) a HP radiating panel for compartment temperature control. The HP augmented cold rail is similar to a standard two-passage fluid cold rail except that it contains an integral, centrally located HP throughout its length. The central HP core helps to increase the local power density capability by spreading concentrated heat inputs over the entire rail. The HP/PCM modular heat sink system consists of a diode HP connected in series to a standard HP that has a PCM canister attached to its mid-section. It is designed to connect a heat source to a structural heat sink during normal operation, and to automatically decouple from it and sink to the PCM whenever structural temperatures are too high. The HP radiating panel is designed to conductively couple the panel feeder HPs directly to a fluid line that serves as a source of waste heat. It is a simple strap-on type of system that requires no internal or external line modifications to distribute the heat to a large radiating area.

Alario, J.↗

NASA NTRS1974

Heat transfer and film cooling following injection through inclined circular tubes

Film cooling effectiveness and heat transfer are measured downstream of injection through discrete holes into a turbulent mainstream boundary layer. Air is injected through both a single hole and a row of holes spaced at three-diameter intervals and inclined at an angle of 35 deg to the main flow. There is little difference between the heat transfer coefficient with blowing and without blowing at low blowing rates (mass flux ratios). In fact, at low blowing rates, injection is found to decrease somewhat the heat transfer coefficient from that measured without blowing. As the mass flux ratio increases past unity, the heat transfer coefficient increases, especially with injection through a row of holes. The peak heat transfer is usually found at the edge of the spreading jets (i.e., between two holes). At a blowing rate near two, the lateral average of the heat transfer is as much as 27 percent higher than the heat transfer with no blowing. The increase in heat transfer is attributed to the interaction between the jets and the free stream, causing high levels of turbulence.

Eriksen, V. L.↗

NASA NTRS1975

Ice pack heat sink subsystem, phase 2

The report describes the design, development, fabrication, and test at one gravity of a prototype ice pack heat sink subsystem to be used eventually for astronaut cooling during manned space missions; the investigation of thermal storage material with the objective of uncovering materials with heats of fusion and/or solution in the range of 300 Btu/lb (700 kilojoules/kilogram); and the planned procedure for implementing an ice pack heat sink subsystem flight experiment. In normal use, excess heat in the liquid cooling garment (LCG) coolant is transferred to a reusable/regenerable ice pack heat sink. For emergency operation, or for extension of extravehicular activity mission time after all the ice has melted, water from the ice pack is boiled to vacuum, thereby continuing to remove heat from the LCG coolant. This subsystem incorporates a quick disconnect thermal interface between the ice pack heat sink and the subsystem heat exchanger.

Roebelen, G. J., Jr.↗

NASA NTRS1976

Effect of a surface-to-gap temperature discontinuity on the heat transfer to reusable surface insulation tile gaps

An experimental investigation is presented that was performed to determine the effect of a surface-to-gap wall temperature discontinuity on the heat transfer within space shuttle, reusable surface insulation, tile gaps submerged in a thick turbulent boundary layer. Heat-transfer measurements were obtained on a flat-plate, single-gap model submerged in a turbulent tunnel wall boundary layer at a nominal free-stream Mach number of 10.3 and free-stream Reynolds numbers per meter of 1.5 million, 3.3 million and 7.8 million. Surface-to-gap wall temperature discontinuities of varying degree were created by heating the surface of the model upstream of the instrumented gap. The sweep angle of the gap was varied between 0 deg and 60 deg; gap width and depth were held constant. A surface-to-gap wall temperature discontinuity (surface temperature greater than gap wall temperature) results in increased heat transfer to the near-surface portion of the gap, as compared with the heat transfer under isothermal conditions, while decreasing the heat transfer to the deeper portions of the gap. The nondimensionalized heat transfer to the near-surface portion of the gap is shown to decrease with increasing Reynolds number; in the deeper portion of the gap, the heat transfer increases with Reynolds number.

Throckmorton, D. A.↗