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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Flash ironmaking drop tube furnace system

A flash ironmaking drop tube furnace includes a primary reaction section having a refractory, an induction coil around the refractory, insulation located between the refractory and the induction coil, and a susceptor located inside the refractory, the susceptor being formed of a material that is heated by induction when electrical current flows through the induction coil, and having at least one interior channel through which particles can pass. The furnace further includes a muffle, located below the primary reaction section; an outer shell surrounding the muffle; at least one heater located adjacent to the muffle; insulation located between the at least one heater and the outer shell; at least one particle feeder that feeds a predetermined volume of particles into the furnace above the primary reaction section; and an inlet port for injecting gas into the furnace, the inlet port being located so that the gas flows through the susceptor and muffle in parallel with the particles.

Green, Edward↗
DOE OSTI2023

Acidic Gas Reduction For Residential Natural Gas Furnace

The United States has more than 119 million homes, and 47% of them rely on natural gas as their primary heating fuel. However, most U.S. homes still use noncondensing units with an annual fuel utilization efficiency (AFUE) of ~80%, rather than efficient condensing furnaces. This is due to the high cost of condensing furnaces, which usually use expensive corrosion resistant super-ferritic stainless steel alloy heatexchangers (HX) to avoid corrosion and fouling acid condensation, along with the cost and difficulty of retrofitting the venting used by the replaced furnace. Here, this article discusses a low-cost acidic gas reduction (AGR) catalyst technology that enables a novel condensing natural gas furnace with an ultraclean (i.e., nearly zero) flue gas and neutral condensate that is environmentally friendly.

03 NATURAL GAS↗
DOE OSTI2017

Improved Casting Furnace Conceptual Design

In an attempt to ensure more consistent casting results and remove some schedule variance associated with casting, an improved casting furnace concept has been developed. The improved furnace uses the existing arc melter hardware and glovebox utilities. The furnace concept was designed around physical and operational requirements such as; a charge sized of less than 30 grams, high heating rates and minimal additional footprint. The conceptual model is shown in the report as well as a summary of how the requirements were met.

42 ENGINEERING↗
DOE OSTI2012

Measure Guideline: High Efficiency Natural Gas Furnaces

This Measure Guideline covers installation of high-efficiency gas furnaces. Topics covered include when to install a high-efficiency gas furnace as a retrofit measure, how to identify and address risks, and the steps to be used in the selection and installation process. The guideline is written for Building America practitioners and HVAC contractors and installers. It includes a compilation ofinformation provided by manufacturers, researchers, and the Department of Energy as well as recent research results from the Partnership for Advanced Residential Retrofit (PARR) Building America team.

03 NATURAL GAS↗
DOE OSTI2012

Measure Guideline: High Efficiency Natural Gas Furnaces

This measure guideline covers installation of high-efficiency gas furnaces, including: when to install a high-efficiency gas furnace as a retrofit measure; how to identify and address risks; and the steps to be used in the selection and installation process. The guideline is written for Building America practitioners and HVAC contractors and installers. It includes a compilation of information provided by manufacturers, researchers, and the Department of Energy as well as recent research results from the Partnership for Advanced Residential Retrofit (PARR) Building America team.

03 NATURAL GAS↗
DOE OSTI2015

Radiation from Large Gas Volumes and Heat Exchange in Steam Boiler Furnaces

Radiation from large cylindrical gas volumes is studied as a means of simulating the flare in steam boiler furnaces. Calculations of heat exchange in a furnace by the zonal method and by simulation of the flare with cylindrical gas volumes are described. The latter method is more accurate and yields more reliable information on heat transfer processes taking place in furnaces.

42 ENGINEERING↗
DOE OSTI2018

Efficient Recovery of Copper and Cobalt from the Matte–Slag Mixture of ISA Furnace by Injection of Coke and Pyrite

During ISA copper smelting process, ISASMELT furnace discharges a large amount of matte and slag mixture and the separation of them has an important influence on the recovery of valuable metals. This paper presented a reduction-sulfurization sedimentation process for recovering copper and cobalt from the matte–slag mixture of ISA furnace. Firstly, matte–slag mixture and traditional static sedimentation slag are characterized to determine their mineral composition and occurrence state. It indicates that Cu is primarily lost in slag in the form of sulfide, while Co is mostly lost in the form of oxide. With coke and pyrite as the reducing agent and vulcanizing agent, an orthogonal laboratory experiment was conducted to determine the effects of the smelting temperature and additive dosage on the recovery process. The optimum slag cleaning conditions were found to be: a coke dosage of 2 pct, a pyrite dosage of 2 pct, and a smelting temperature of 1260 °C lasting for 2 hours. In order to improve on the low utilization ratio of additives associated with the industrial sedimentation process, an innovative additive introducing method was put forward which enables the additives to mix and react with slag more adequately. A powder injection device was purpose-made to inject additives into molten slag in dispersion state, and a laboratory experiment was carried out to simulate this process. By injecting 2 pct coke and 2 pct pyrite, the contents of Cu and Co in cleaned slag decreased to 0.46 and 0.01 pct, respectively. It proves that the injection of additives into molten slag is an effective method to recover Cu and Co from the matte–slag mixture of ISA furnace.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Study of Plume Eye in the Copper Bottom Blown Smelting Furnace

In the present study, the plume eye, which is a gas bubble plume generated by pushing away the upper layer liquid having a lower density and the exposure of the lower layer liquid which has a relatively higher density, was studied systematically in a bottom blown furnace model. A series of single lance experiments were carried out in a horizontal cylindrical furnace model to evaluate the effects of gas flowrate, lower layer thickness and upper layer thickness on the size of plume eye. The corresponding eye areas under different experimental conditions were measured. The results suggest that the eye size increases with increase of the gas flowrate and lower layer thickness. On the other hand, the eye size is reduced with increasing upper layer thickness. A mathematical model has been developed to predict the eye area in a horizontal cylindrical furnace by a single bottom blown lance.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Skin and Proximity Effects in Electrodes and Furnace Shells

A review of two-dimensional (2D) analytical models of skin and proximity effects in large industrial furnaces with three electrodes arranged in an equilateral triangle is given. The models cover three different cases: one electrode only, three electrodes where two are approximated by line currents, and induced shell currents where all electrodes are approximated by line currents. The first two models show how the skin and proximity effects depend on electrode material properties and size, and the distance between the electrodes. The third model shows how the strength of the induced shell currents will depend on electrode position and furnace size. These models are compared to numerical studies including distributed electrodes and shell currents. The analytical models are accurate when induced shell currents can be disregarded. However, strong shell currents may have a significant impact on the current distribution within the electrodes. This electrode-shell proximity effect competes with the electrode-electrode proximity effect. Finally, the 2D models have been compared with three-dimensional (3D) case studies of large industrial furnaces. In 3D, the shell currents are significantly smaller than what are predicted by the 2D models, but they are sufficiently strong to cause a significant correction of the electrode current density.

36 MATERIALS SCIENCE↗
DOE OSTI2019

Determination of the Charge Materials Range in Multistage Charge Burden Optimization for Foundry Furnaces

Optimization of charge burden for foundry furnaces lies in determining a percentage or mass (kg, t) of the share of each charge material in the burden with the lowest unit cost. A classic task of charge burden optimization requires a definition of an objective function, which most often defines the cost of the charge burden and a system of constraints, including technological assumptions such as the balance of chemical elements for the required chemical composition of the charge or molten metal, limitations of the mass fraction of the individual elements of the charge, and others. The solution for such an optimization task is a set of starting values for the devices which weigh and proportion the charge materials for a foundry furnace. The consequences of deviations from proper values, causes by inaccurate weighing or proportioning and human error as well, can be limited by using an appropriately designed and implemented multistage optimization algorithm. This article presents a mathematical model of such an algorithm and discussion of its practical application. The algorithm as described below can be an important element of computer-aided decision to be made by employees in the process of batch compilation or automatically control devices dosing individual batch components. An IT system with an implemented algorithm may significantly increase the efficiency of charge preparation for a foundry furnace, guaranteeing its correct chemical composition despite batch materials dosing errors. It will contribute to a significant improvement of economic indicators of liquid metal production, with the effect of boosting the competitiveness of the foundry industry.

36 MATERIALS SCIENCE↗
DOE OSTI2012

Synthesis of homogeneous Ca{sub 0.5}Sr{sub 0.5}FeO{sub 2.5+{delta}} compound using a mirror furnace method

Graphical abstract: X-ray diffraction pattern indexing of Ca{sub 0.5}Sr{sub 0.5}FeO{sub 2.5+{delta}} powder sample obtained by mirror furnace method after thermal treatment. Highlights: Black-Right-Pointing-Pointer A homogenous compound Ca{sub 0.5}Sr{sub 0.5}FeO{sub 2.5+{delta}} has been synthesized for the first time by a mirror furnace method. Black-Right-Pointing-Pointer Ca{sub 0.5}Sr{sub 0.5}FeO{sub 2.5+{delta}} powder sample is perfectly homogenous, confirmed by X-ray diffraction, Raman spectroscopy and EDS technique. Black-Right-Pointing-Pointer The thermal treatment of Ca{sub 0.5}Sr{sub 0.5}FeO{sub 2.5+{delta}} powder sample can increase their average grain sizes. -- Abstract: A new synthesis method using melting zone technique via the double mirror furnace around 1600 Degree-Sign C is used to obtain homogenous brownmillerite compounds Ca{sub 1-x}Sr{sub x}FeO{sub 2.5+{delta}} in the range 0.3 {<=} x {<=} 0.7. These compounds play important role in understanding the mystery of the oxygen diffusion in the perovskite-related oxides. We have successfully solved the miscibility gap problem by synthesizing a good quality of homogenous powder samples of Ca{sub 0.5}Sr{sub 0.5}FeO{sub 2.5+{delta}} compound. Our result was confirmed by X-rays diffraction, Raman spectroscopy and energy dispersive spectroscopy analysis. Thermal treatment was also applied until 800 Degree-Sign C under vacuum to confirm again the homogeneity of powder samples, improve its quality and show that no decomposition or return to form Ca- and Sr-enriched microdomains takes place as a result of phase separation.

36 MATERIALS SCIENCE↗
DOE OSTI2025

Advancing Temperature Monitoring of the Bottom Anode in a Direct Current Electric Arc Furnace Operations with Distributed Optical Fiber Sensors.

The bottom anode in the Direct Current Electric Arc Furnace (DC EAF) is critical for completing the electrical circuit necessary for sustaining the arc within the furnace. For pin-type bottom anodes, monitoring of the temperature of select pins instrumented with thermocouples is performed to track bottom wear in the EAF and inform the operator when the furnace should be removed from service. Furthermore, this work presents the results from a plant trial using distributed temperature monitoring of bottom anode pins in a 165-ton DC EAF over a two-month service period utilizing two optical fiber sensing techniques: fiber Bragg grating (FBG) and Rayleigh backscattering (RBS). The early detection of temperature anomalies along the length of the anode pin through distributed sensing enhances operational safety, providing a robust alternative to traditional thermocouples.

42 ENGINEERING↗
DOE OSTI2014

Numerical Methods for Simulating the Reduction of Iron Ore in Blast Furnace Shaft

The blast furnace process is a counter-current moving bed chemical reactor to reduce iron oxides to iron, which involves complex transport phenomena and chemical reactions. The iron ore and coke are alternatively charged into the blast furnace, forming a layer by layer structural burden which is slowly descending in the counter-current direction of the ascending gas flow. We proposed a new methodology to efficiently simulate the gas and solid burden flow in the counter current moving bed in blast furnace shaft. The gas dynamics, burden movement, chemical reactions, heat and mass transfer between the gas phase and solid phase are included. Furthermore, the new methodology has been developed to explicitly consider the effects of the layer thickness thermally and chemically in the CFD model.

42 ENGINEERING↗
DOE OSTI2025

Flexible Fuel Electric Hybrid Glass Furnace Demonstration

The furnace contractor completed General Arrangement (GA) layouts and Piping and Instrumentation Diagrams (P&ID) for both furnaces during this reporting period. Preliminary equipment lists accompanied this work. Control system architecture in progress. Key furnace design elements and deliverables on track to be complete by end of phase. The facilities design and integration contractor completed a 3D scan and modeling of the facility. The work during this period focused on preliminary design with a focus on overall project scope and feasibility. This key work supports the overall project deliverables for 30% preliminary engineering and Preliminary Design Report (PDR) which are on track to be complete by the end of the phase. These deliverables are approximately 50% complete through the end of this reporting period. The batch house operations design contractor continues development of site plan and General Arrangement (GA) layout to support the 30% preliminary engineering and design package. This work is 60% complete by the end of this reporting period and is on track to be complete by the end of the phase.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2025

Glass Furnace Decarbonization Technology Stack (Final Technical Report)

This report summarizes the objectives, approach, and outcomes of the Glass Furnace Decarbonization Technology Stack project undertaken by Owens-Brockway Glass Container Incorporated under award number DE-CD0000093. The project aimed to implement a pioneering combination of furnace technologies at the Zanesville, OH manufacturing site to reduce carbon intensity (CI) by 20–40% compared to baseline operations. The proposed Furnace Technology Stack included a Gas/Oxy-fuel system, OPTIMELT™ Heat Recovery System, raw material pre-heating, electric boosting, and forehearth electrification—designed to demonstrate commercial feasibility and drive industry-wide decarbonization.

42 ENGINEERING↗
DOE OSTI2024

Enhanced Bottom Anode Monitoring in DC Electric Arc Furnaces Using Fiber-Optic Sensors

A pin style bottom anode employs conductive steel rods that serve as the pathway for the high electrical power through rammed refractory at the bottom of a DC Electric Arc Furnace (EAF). Anode wear during operation is important to monitor, as anode replacement is expensive and impacts EAF productivity. Liquid steel penetration into the un-sintered refractory layer can result from rapid electrical power ramp-up, dips in furnace temperature, or operating the anode for too long between EAF campaigns. In extreme cases, the liquid steel may penetrate the bottom of the furnace when anode wear progresses too close to the bottom shell, which is extremely dangerous and must be avoided. The current state of the art for monitoring bottom anode wear employs thermocouples imbedded in the anode pins at points in the anode. However, this approach is not sensitive enough to detect localized damage to the anode, especially when cracking occurs. Here, the present work utilizes fiber optic sensors to monitor the health of the anode, by creating a real-time spatially distributed temperature map of the anode. Unlike the traditional thermocouples, these sensors can be mounted at significantly greater depths, provide distributed temperature measurements, and can withstand temperatures of up to 900°C. Additionally, they are able to perform temperature measurements with a spatial resolution of 1.3 mm at a 5 Hz acquisition rate, providing unprecedented high-density real time monitoring of anode health and increasing the efficiency, and safety of EAF operation.

Bottom Anode↗
DOE OSTI2023

Machine Learning-Based Regression Models for Ironmaking Blast Furnace Automation

Computational fluid dynamics (CFD)-based simulation has been the traditional way to model complex industrial systems and processes. One very large and complex industrial system that has benefited from CFD-based simulations is the steel blast furnace system. The problem with the CFD-based simulation approach is that it tends to be very slow for generating data. The CFD-only approach may not be fast enough for use in real-time decisionmaking. To address this issue, in this work, the authors propose the use of machine learning techniques to train and test models based on data generated via CFD simulation. Regression models based on neural networks are compared with tree-boosting models. In particular, several areas (tuyere, raceway, and shaft) of the blast furnace are modeled using these approaches. The results of the model training and testing are presented and discussed. The obtained R 2 metrics are, in general, very high. The results appear promising and may help to improve the efficiency of operator and process engineer decisionmaking when running a blast furnace.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2022

Modeling and Analysis of a Thermophotovoltaic Integrated Self-Powered Furnace

This work investigates the energy efficiency and carbon reduction potential of self-powered residential building heating equipment using a thermodynamic modeling approach. An integrated thermophotovoltaic power module and residential scale furnace system (40,000 Btu/h) were modeled and studied in detail to assess the influence of different design configurations on primary energy efficiency. Operational characteristics such as total power generation, electrical efficiency, and heat recovery were examined in a self-powered system configuration. A sensitivity analysis was conducted to determine the influence of the electric grid’s carbon dioxide footprint (carbon intensity) and the cost of electricity on the environmental, as well as the economic, benefit associated with the self-powered configuration. Compared with a traditional furnace powered by an electric grid at a carbon intensity of 0.5 kg CO 2eq /kWh EL , the self-powered furnace was shown to decrease the annual carbon dioxide emissions by approximately 550 kg (~75% reduction), while also saving more than USD 200 in utility expenses, annually. Additionally, the carbon emission reduction potential of blending different concentrations of hydrogen in natural gas fuel was also studied.

14 SOLAR ENERGY↗