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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 OSTI2021

Evaluating the effects of a low-carbon energy transition on existing U.S. fossil energy communities

On-going efforts and the growing movement to transition from our current energy systems towards low-carbon and renewable sources have uncovered a range of challenges and concerns communities may face under this transition. An understanding of the current relationships and dynamics within communities can offer critical insights that stakeholders, as well as decision and policy makers can use to better support and affect the outcome of these transitions. To support this need, the National Energy Technology Laboratory has been developing a data-driven framework to aid in the characterization of fossil energy communities across the U.S. and offer insights to comprehensively address energy transaction concerns by different stakeholder groups and various stages associated with a low-carbon energy system. This presentation will offer details on our current work to integrate multiple environmental, social, and economic data variables, as well as key trends and insights that are being used to characterize these communities at a local and regional scale. These insights will be used to evaluate with alternative opportunities, including, but not limited to, hydrogen, rare earth elements and critical minerals, and energy storage, that could be aid in the transition for these communities from conventional energy resources.

Bauer, Jennifer↗
DOE OSTI2024

Does How we Decarbonize Matter? An Examination of the Potential Energy Poverty Impacts of Fossil Asset Replacements

Replacing fossil assets with low-carbon alternatives will influence the costs associated with maintaining a competent, reliable grid (i.e., total systems costs). Noting over time any resulting system cost increases will likely be borne by consumers, this paper aims to provide insight into the potential energy poverty impacts that may result.

Harker Steele, Amanda [NETL] (ORCID:00000003233986↗
DOE OSTI2026

Thermal analysis of combustion synthesis of FeAlxOy catalysts for dehydrogenation of fossil fuels

The growing demand for hydrogen as a clean energy carrier highlights the need for its alternative production method with reduced CO₂ emissions. Microwave-assisted thermocatalytic dehydrogenation of fossil fuels offers a promising solution for clean hydrogen production, with FeAlxOy nanocomposites acting as efficient catalysts due to their thermal stability, catalytic activity, and microwave-absorption properties. FeAlxOy nanocomposites, fabricated by solution combustion synthesis (SCS), have shown good microwave-absorption and catalytic properties. However, the effects of synthesis parameters such as fuel type and Fe:Al molar ratio on the SCS process and properties of the final material are not well understood. The SCS process involves vaporization of water, thermal decomposition of the mixture components, and oxidation – reduction reactions. In the present work, thermogravimetric analysis (TGA) and differential scanning calorimetry (DSC) were utilized to study the SCS mechanism, with a focus on understanding decomposition processes. TGA provided insights into the thermal stability and mass loss profiles of the mixtures, while DSC quantified the heat release and identified reaction onset temperatures. Results demonstrated that the choice of fuel significantly influenced the thermal behavior and properties of FeAlxOy nanocomposites. Glycine-based mixtures exhibited superior thermal stability and complete decomposition in a single step with high heat release compared to citric acid-based mixtures, which required higher synthesis temperatures and experienced slower, two-step decomposition processes. These findings emphasize the effectiveness of glycine-fueled SCS in producing thermally stable and catalytically active FeAlxOy nanocomposites.

Martinez Espinoza, Laura Alejandra↗
DOE OSTI2022

Fabrication and Characterization of Iron-Based Catalysts for the Dehydrogenation of Fossil Fuels

For a prosperous and sustainable future, hydrogen is an encouraging solution due to its simple transition for industrial decarbonization and synergy for economic development. Paradoxically, current hydrogen production pathways release substantial amount of greenhouse gases into the atmosphere contributing to climate change. To keep up with increasing demand, hydrogen could be produced through microwave-assisted thermocatalytic dehydrogenation of fossil fuels without emitting carbon dioxide. This requires specified catalysts to meet the requirements of hydrogen yield and selectivity. The objective of the present research is to fabricate, characterize, and compare iron-based alumina (FeAlxOy) catalysts produced via solution combustion synthesis and iron-based catalysts on silicon carbide support (Fe/SiC) produced via incipient wetness impregnation. Heat mode, fuel type, and oxidizer mole ratio were varied for FeAlxOy catalysts, and metal loading was varied for Fe/SiC catalysts. Each resultant product was characterized by X-ray diffraction analysis, scanning electron microscopy, laser diffraction particle size analysis, and Brunauer-Emmett-Teller (BET) surface area analysis. Characterization suggests that fabrication of iron-based alumina nanocomposites through solution combustion synthesis in a muffle furnace using citric acid as the fuel yields the most promising catalyst.

Reyes, Victoria Isabel↗
DOE OSTI2023

Solution combustion synthesis of iron-based alumina catalysts for dehydrogenation of fossil fuels

Microwave-assisted thermocatalytic dehydrogenation of fossil fuels has been proposed as a method for hydrogen production with no CO2 emissions. The byproduct is carbon, which has a commercial value. Iron-based alumina nanocomposites are promising catalysts for this process as they both absorb microwave radiation and catalyze the dehydrogenation. In addition, they may have magnetic properties, which could be used for their separation from the carbon byproduct. Solution combustion synthesis (SCS) is an attractive technique for the fabrication of iron-based alumina nanocomposites because it can produce high specific surface area oxides in a facile manner. However, the effects of the heating mode, the fuel, and the iron/aluminum ratio on the combustion synthesis behavior and the product properties have not been studied yet. In the present work, the iron-based alumina nanocomposites were obtained by SCS using a hotplate, a muffle furnace, and a microwave oven. The initial mixtures were aqueous solutions of iron nitrate, aluminum nitrate, and an organic fuel. The concentrations of the two nitrates were varied in proportion to Fe:Al molar ratios of 1:2, 1:1, and 2:1. Two fuels were tested: citric acid and glycine. The combustion was less vigorous when citric acid was used as the fuel, which is explained by the lower exothermicity of the reaction. X-ray diffraction analysis of the products confirmed the formation of complex oxides of Fe and Al, specifically it detected hercynite and magnetite phases. Brunauer-Emmett-Teller surface area analysis has shown that the powders obtained using citric acid have specific surface areas as high as 276 m2/g, significantly higher than those obtained using glycine. Muffle furnace and hotplate heating led to comparable specific surface areas, while microwave heating resulted in significantly lower specific surface areas. The magnetic properties of the products increase with increasing the Fe/Al molar ratio from 1:2 (no response to a magnetic field) to 1:1 (weak response) and 2:1 (strong response).

solution combustion synthesis, nanoscale oxides, f↗
DOE OSTI2022

Solution combustion synthesis of iron-based alumina nanocomposites for clean production of hydrogen from fossil fuels

Iron-based alumina nanocomposites are promising materials for microwave-assisted thermocatalytic dehydrogenation of fossil fuels, which has been proposed for the production of hydrogen with no CO2 emissions. Solution combustion synthesis (SCS) is an attractive technique for the fabrication of these materials because it has been used for synthesis of many nanoscale oxides. However, SCS can be carried out using different organic fuels and different heating equipment, and it is important to determine which fuel and heating mode generate materials with the best properties for dehydrogenation, such as maximized specific surface area. In the present work, the iron-based alumina nanocomposites were obtained by SCS using two different fuels (citric acid and glycine) and two different heating modes (a hotplate and a muffle furnace). The precursors/oxidizers were iron nitrate and aluminum nitrate. They were mixed with the fuel according to stoichiometry and dissolved in water. Heating the solution resulted in combustion synthesis. The products were characterized by X-ray diffraction analysis, Brunauer-Emmett-Teller surface area analysis, laser diffraction particle size analysis, scanning electron microscopy, and energy dispersive X-ray spectroscopy. The experiments have shown that the specific surface area of the iron-based alumina nanocomposites obtained by SCS can be dramatically increased by using citric acid instead of glycine, and additionally by using a muffle furnace instead of a hotplate.

Solution combustion synthesis, Nanoscale metal oxi↗
DOE OSTI2023

Treatment of brackish water for fossil power plant cooling

In this study, we evaluated the technical, economic and environmental impacts of retrofitting brackish groundwater treatment systems at existing coal- and gas-fired electric generating units (EGUs) to reduce freshwater consumption in wet cooling towers. Based on fleet averages, retrofitting brackish water treatment systems decreases unit freshwater consumption by 94–100%, while increasing the cost of electricity generation by 8–10%. The unit capacity shortfalls are less than 1.1%. The resulting cost of freshwater consumption savings by brackish water treatment is US$1.7 m -3 and US$2.9 m -3 on average for coal- and gas-fired EGUs, respectively. However, these trade-offs are highly affected by the brine disposal method. The use of thermal zero liquid discharge for brine disposal can roughly double the average cost of freshwater consumption savings. The cost-effectiveness of brackish water treatment compared with dry cooling deployment depends on how concentrated brines are managed. In conclusion, the identified trade-offs and their dependence fill knowledge gaps to better inform water management.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2020

Integrated Harsh Environment Gas / Temperature Wireless Microwave Acoustic Sensor System for Fossil Energy Applications

There is a significant need for sensors capable of detecting gases, such as H 2 , O 2 , NO x , SO x within harsh environments encountered in power plants, industrial manufacturing, oil and gas exploration, and aerospace applications. This project successfully demonstrated the use of wireless microwave acoustic sensor technology for the detection of gases (H 2 or O 2 ) from ambient temperatures up to 650°C. The work focused on langasite (LGS) based surface acoustic wave resonator (SAWR) sensors as the harsh-environment sensor platform and explored multiple combinations of high-temperature thin films and device structures which were used to increase the sensor platform stability and detection capability at temperatures in the operational range of 150°C to 700°C. Specific material configurations that were investigated include: yttria-stabilized-zirconia (YSZ) decorated with Pt nanoparticles, atomic layer deposited (ALD) Al 2 O 3 , palladium, and Pt/Al 2 O 3 co-deposited electrode alloys. Through the deposition of YSZ at temperatures as high as 850°C and the use of graded alloy concentrations of Pt in the fabrication of the Pt/Al 2 O 3 electrode structures, film stress problems were mitigated, and sensor operation and stability achieved. To test and evaluate SAWR sensor performance for the detection of H 2 and O 2 under the influence of temperature variations, a comprehensive gas sensor control system and test apparatus was created to operate within a laboratory box furnace-controlled environment. In addition to the advancement in thin film materials through the deposition and fabrication techniques mentioned above, the work characterized the performance of sensors containing these films in the presence of oxidizing and reducing gases between 25°C and 700°C. In particular, the work revealed that the exposure of the SAWR sensor surfaces to oxidizing environments significantly improve the sensor response to H 2 , whereas the exposure of the sensor to reducing environments at high temperatures (≈ 500°C) renders the sensor irresponsive to H 2 , requiring sensor surface treatment at high temperatures (above 500°C) to recover the responsiveness to H 2 . The SAWR sensors have been also tested for wireless operation and array operation using multiple orientations to resolve the detection of gases under temperature variations. The work developed at the University of Maine was aided by a collaboration with the NETL Research and Innovation Center, Pittsburgh, PA, where thin film materials and device structures fabricated at UMaine were tested and characterized using NETL gas reactors and surface analysis techniques. SAWR sensors fabricated at UMaine were exposed multiple times to temperatures up to 700°C and H 2 concentrations up to 100% in the NETL facilities to measure the sensor performance. Environetix Technologies Corporation, a UMaine harsh-environment sensor spin-off company, also provided support and assistance in sensor system testing and implementation. The sensor small size and configuration allows flexible sensor placement and embedding of multiple sensor arrays into a variety of components within power systems and other aerospace or industrial settings that need to be interrogated wirelessly. The SAW platform is an attractive option for high-temperature harsh-environment gas sensing applications due to its inherent features, namely small size, capability of battery-free and wireless operation, and cost effective scale production using well-established production techniques from the semiconductor industry. The research findings achieved in this work, particularly advances regarding the fabrication and performance of the SAWR gas sensor platform, can be adapted and transferred to industrial power plants and other harsh environments.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2020

The Novel Hybrid Ab Initio Model of High-Performance Structural Alloys Design for Fossil Energy Power Plants

The current project developed a novel HT-CALPHAD/DFT approach, which can quickly design new high-performance structural alloys for the application of FE power plants. The PI will mainly take charge of high-throughput DFT simulations and computational thermodynamics of the selected multicomponent alloy systems for the FE power plant applications. At the end of the project, a novel hybrid model based on high throughput CALPHAD/DFT simulations and computational thermodynamics will be developed to provide guidance on how to identify multi-component new high-performance structural alloys with much less computational effort needed. It will address the extensive computation time needed for DFT on the new alloys design. In addition, it will also address the well-known headache of DFT, i.e. how to make the accurate prediction of the high-temperature equilibria. The novel hybrid model the PI proposed will not only be applied to the design of high-performance structural alloys in FE power plants but in many different applications, such as nuclear reactors. This hybrid modeling approach includes four sections: 1) HT-CALPHAD modeling of Al-Co-Cr-Ni-Fe system with FCC and BCC phase. In this section, 3561 non-equiatomic compositions were randomly generated in order to investigate the phase stability of single FCC and BCC phases. Meanwhile, we proposed a data screening procedure to screen out the good candidates within these compositions, considering the temperature range, average density, and melting temperature, etc. 2) Investigation of FCC-Cr lattice stability in Fe-Cr system. We systematically assessed the reliability of FCC-Cr lattice stability derived by DFT and CALPHAD approaches. Meanwhile, the Fe-Cr binary system was chosen as a case study to verify the Cr lattice stability obtained by both approaches. 3) High-throughput DFT modeling on elastic properties of Al-Co-Cr-Ni-Fe systems. We predicted and established the FCC quinary elastic constant database of the Al-Co-Cr-Fe-Ni systems at 0K by using special quasi-random structure (SQS) approach. The predictions will start with pure elements of Al-Co-Cr-Fe-Ni system and will be continued with binaries, ternaries, quaternaries, and finally the quinary compositions. 3) Modeling of temperature-dependent elastic properties in Al-Co-Cr-Ni-Fe systems. In this part, we predict the thermal expansion coefficient and elastic stiffness coefficient as a function of temperature by applying quasiharmonic approximation. With this approach, the elastic properties of HEAs at elevate temperature can be estimated.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2020

Cyber Secure Sensor Network for Fossil Fuel Power Generation Assets Monitoring

The energy sector is undergoing digital transformation which is to say more and more power generation assets have become automated and connected to the internet. The connected sensors can tap into plants to monitor the health of assets and manage fleets remotely. These are just some of the benefits digitalization is bringing to the power industry. Within a power plant, control systems are no longer concerned with one system or one piece of equipment, but rather whole fleet of assets inter-connected with smart sensors which have the function of continuously monitoring and transmitting real-time operational data to operators. These connected systems will form a part of the industrial internet of things (IIoT). The big data scenarios provide benefits of performing system prognostics and optimization which is a key selling point of power plant digitalization.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2021

An Accelerated Creep Testing (ACT) Program for Advanced Creep Resistant Alloys for High Temperature Fossil Energy (FE) Applications (Final Report)

The research objective of this study is to develop an accelerated creep testing (ACT) program for advanced creep resistant alloys for high temperature FE applications. This research produced a new ACT for metallic materials based on Time-Temperature-Stress Superposition (TTSSP). In TTSSP, there exists a fundamental relationship between creep resistance, time, temperature, and stress that can be manipulated to reduce test durations. In our study, the stepped isostress method was employed where step increases of load during creep testing accelerated the time-to-rupture. Well-posed constitutive models including sin-hyperbolic and Wilshire-Cano-Stewart where calibrated using the SSM data and employed to predict the conventional creep response of the material. In our best experiments, <100-hour tests on lnconel 718 at 750 deg C produced over a 64x acceleration of data when compared to conventional data from Japan's National Institute of Materials Science. The ACTs enable the rapid screening of candidate materials, where a small test matrix of short duration tests can be employed to determine the creep resistance (minimum-creep-strain-rate, stress-rupture, and creep deformation) of a material across decades.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2022

Integrated Computational Materials and Mechanical Modeling for Additive Manufacturing of Alloys with Graded Structure Used in Fossil Fuel Power Plants

Wire-arc additive manufacturing (WAAM) has demonstrated its unique capability of producing large-size alloy components with a significantly reduced fabrication time and enhanced geometry design freedom. In this project, the team has developed an ICME (Integrated Computational Materials Engineering) modeling framework, which supports the WAAM of the AUSC (Advanced Ultra-Supercritical) power plant components. The manufacturing design has been applied to Inconel 740H, steel P91, as well as the dissimilar alloy components between steel P91 and Inconel 740H. The ICME model framework is developed by considering two types of modeling. First, mechanistic modeling has been applied to control the printing quality and understand the sequence of the dissimilar printing of the wall structure. The following models have been included in the developed ICME framework: finite element thermal model, grain structure model, residual stress simulation, crystal plasticity model, CALPHAD-based precipitation kinetic model, phase stability prediction, thermal expansion predictive model, and heuristic creep model. Secondary, a physics-based machine learning model has also been developed based on the ICME model structure. The machine learning model development is based on the ICME model prediction with calibration of the experiments. In addition, the WAAM has been utilized as a high-throughput experimental tool rapidly generating a gradient of alloy composition to facilitate experimental database generation for process-structure-property relationships. Such a database directly supported the ICME-enhanced machine learning, which further assisted in intermediate composition block design between P91 and 740H. A high-throughput screening study of the oxidation resistance has been performed based on such high-throughput experimentation. Based on the computational design, several dissimilar alloy manufacturing with post-heat treatment have been performed with a comprehensive evaluation of mechanical performance, including hardness mapping, yield strength, creep resistance. In this project, the single component of P91 and 740H processed by WAAM after heat treatment designed by ICME has demonstrated higher performance in yield strength and creep resistance than the wrought materials. The P91 sample prepared by WAAM with ICME-designed heat treatment performs better than P92 in creep resistance. The designed graded alloy printing with intermediate block shows a promising performance that exceeds the traditional welding. Moreover, the current research indicates the high need for location-specific design analysis with uncertainty quantification, an important topic that deserves more dedicated research. The achievement of this project demonstrated the promising future of WAAM in structural alloy manufacturing for energy power plant development. Successful printing requires synergetic efforts made by manufacturing, mechanical, and materials sciences.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2022

UK-US Collaboration on Fossil Energy R&D: Steam Side Oxidation

In recent years, interest in increasing the efficiency of power plants based on steam generation has led to the need to develop and qualify materials capable of operating at steam temperatures and pressures significantly higher than those employed in current power plants. The overall focus of this international program is on using ferritic-martensitic steels to the maximum possible temperature, before switching to austenitic steels and/or Ni-based alloys. The relatively low Cr content of these alloys raises concerns regarding their resistance to steam oxidation at these higher temperatures. Earlier work in this collaboration addressed the reliability of data from atmospheric pressure, laboratory-based steam oxidation tests. This raised issues regarding how representative the laboratory-grown oxides were compared to those formed on service-exposed material and how the tests could be made more reliable by introducing added complexity. In general laboratory-scale exposures are conducted under isothermal conditions at ambient or slightly elevated pressure, using a relatively low flow rate of steam. The coupons used in these tests are normally flat cuboids which have been ground to homogenise the surface and remove any pre-existing features. However, there is a concern that these samples and exposures are not representative of service conditions, and so it is necessary to quantify the influence of transient conditions, such as heat flux, pressure and sample geometry/surface conditions. To address such concerns a new collaborative program of work was initiated to determine the influence of these added features on oxidation kinetics and oxide scale morphology. The overall aim was to improve the understanding of alloy performance in ultrasupercritical (USC) steam conditions and qualify suitable test procedures.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2023

Techno-Economic and Deployment Analysis of Fossil Fuel-Based Power Generation with Integrated Energy Storage

Most existing coal-fired power plants were designed for sustained operation at full load to maximize efficiency, reliability, and revenues. Depending on plant type and design, these plants can adjust output within a fixed range in response to plant or market conditions. The need for flexibility driven by increased penetration of variable and non-dispatchable power generation such as wind and solar is shifting traditional mission profile of thermoelectric power plants in three ways: more frequent shutdowns when market or grid conditions warrant, more aggressive load ramp rates (rate of output change), and lower minimum sustainable load, which provides a wider operating range and helps avoid costly plant shutdowns. The recent studies have shown that flexibility of a coal-fired power plant can be improved by the energy storage. The objective of this project was to analyze a set of energy storage options (technologies) and determine their impact on flexibility and economics of a representative coal-fired power plant. The effect of five Energy Storage Systems (ESSs) integrated with a coal power plant on plant flexibility and economics was investigated in this study. The results obtained in this project and presented in this report showed that ESS integrated with a thermal power plant improves plant flexibility and participation in the Energy and Ancillary Services markets and also improves plant financial performance.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2022

Development of a Pipe Crawler Inspection Tool for Fossil Energy Power Plants

This document presents the final report of the research activity completed during the four years of the project and includes the major challenges and accomplishments. The report presents specific details of the engineering processes and methodologies used to develop the robotic crawler and complete the project milestones. In particular, the report includes sections that address the problem statement, background, development of crawler modules, bench scale testing, simulation development and full scale testing. The report concludes with a discussion on potential paths forward and concluding remarks.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2025

Ultra-Low Disorder Graphene Quantum Dot-Based Spin Qubits for Cyber Secure Fossil Energy Infrastructure (Final Technical Report)

The overarching goal of the proposed project is to demonstrate the feasibility of creating ultralow local disorder graphene quantum dots (GQDs)-based high-speed, high-fidelity spin quantum bits (qubits) for extremely cyber-secure coal energy plants of the future. Despite their inherent benefits, the coherence times in the state-of-the-art GQD qubits are still low primarily due to the local disorder in GQD devices generated during lithographic fabrication of GQDs. Hence, the focus of this research is to prepare ultralow disorder GQDs (e.g., edge roughness ~0.5nm) and evaluate the low temperature (~mK) charge/spin transport characteristics of the engineered GQD qubit platform. To achieve minimal disorder in GQD qubits, we employ a novel approach that combines nanotomy (novel GQD fabrication technique developed by the PI) and scanning probe microscopy-atomic oxidation lithography (SPM-AOL).

20 FOSSIL-FUELED POWER PLANTS↗