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At least 1,351 records · Page 75

A Green’s Function Sensor Fusion Approach for Evaluating Spacecraft Entry Heating From on-Board Thermal Instrumentation

During atmospheric entry, distributed thermal measurements are critical to enable the evaluation of heat loads on spacecraft thermal protection systems (TPS). In recent space exploration missions, Schmidt-Boelter-type heat flux gauges have been integrated into the TPS alongside conventional temperature measurement instrumentation to measure total (convective and radiative) and radiative heat transfer rates1,2. While direct heat flux sensors (HFS) are able to provide valuable information detailing the thermal loads experienced by spacecraft, the interpretation of these measurements in unsteady, convective environments requires a correction factor to account for local heating augmentations at the cold wall HFS surface2,3. Current efforts to estimate cold wall correction factors, and thus recover the hot wall TPS heat flux, rely on time-marching computational fluid dynamics (CFD) simulations2. Simulation-based methods are susceptible to large uncertainties, however, as they require estimations of vehicle trajectory, gas kinetics, wall catalysis models, and other flight conditions as input parameters2,4. Furthermore, CFD simulations are computationally expensive and cannot efficiently survey all possible entry scenarios, exacerbating the uncertainty of reconstructed hot wall heat flux values. These drawbacks motivate the development of alternative hot wall heat flux reconstruction methods that are not reliant on CFD-based correction factors.

Kenneth McAfee↗

A Green’s Function Sensor Fusion Approach for Evaluating Spacecraft Entry Heating From on-Board Thermal Instrumentation

During atmospheric entry, distributed thermal measurements are critical to enable the evaluation of heat loads on spacecraft thermal protection systems (TPS). In recent space exploration missions, Schmidt-Boelter-type heat flux gauges have been integrated into the TPS alongside conventional temperature measurement instrumentation to measure total (convective and radiative) and radiative heat transfer rates1,2. While direct heat flux sensors (HFS) are able to provide valuable information detailing the thermal loads experienced by spacecraft, the interpretation of these measurements in unsteady, convective environments requires a correction factor to account for local heating augmentations at the cold wall HFS surface2,3. Current efforts to estimate cold wall correction factors, and thus recover the hot wall TPS heat flux, rely on time-marching computational fluid dynamics (CFD) simulations2. Simulation-based methods are susceptible to large uncertainties, however, as they require estimations of vehicle trajectory, gas kinetics, wall catalysis models, and other flight conditions as input parameters2,4. Furthermore, CFD simulations are computationally expensive and cannot efficiently survey all possible entry scenarios, exacerbating the uncertainty of reconstructed hot wall heat flux values. These drawbacks motivate the development of alternative hot wall heat flux reconstruction methods that are not reliant on CFD-based correction factors.

Kenneth McAfee↗

Artemis I Space Launch System Base Heat Shield Thermal Protection System Performance

The Space Launch System (SLS) Core Stage base heat shield experienced the highest external heating environments on the entire launch vehicle during Artemis I ascent flight. This result was consistent with design predictions. The base heat shield experiences P50 cork combustion dynamics at low altitudes, plume-induced recirculation at moderate altitudes and then in-space base flow physics out to Main Engine Cut-Off (MECO). The base heat shield thermal protection system (TPS) is composed of a P50 cork ablator which is bonded to a substrate. The heat shield protects the gimbal actuation system, RS-25 turbomachinery systems and other aft section sensitive components during ascent. This paper estimates the base heat shield TPS performance from Artemis I using flight data from the NASA Langley Research Center’s Scientifically Calibrated In-Flight Imagery (SCIFLI) Airborne Multispectral Imager (SAMI), development flight instrumentation (DFI) and other TPS recession flight measurements. Predictions from computational and ground test-derived engineering ablation models and observations are also applied. Since no base heat shield substrate thermocouple data were obtained for Artemis I, an estimate of the TPS performance data is derived here. This data assesses thermal margin of the SLS Core Stage base heat shield and best informs the Artemis II Crewed mission to the moon.

aerothermodynamics↗

Apparatus and method for intrachannel defouling of a heat exchanger using induction heaters

An apparatus comprising a heat exchanger and one or more induction heating elements is disclosed. The heat exchanger comprises a coolant side conduit and a process side conduit, the process side conduit being susceptible to fouling by at least partial desublimation, condensation, crystallization, deposition, or combinations thereof of a fouling component of a circulating process fluid. An electrically conductive first metal is disposed adjacent to the process side conduit. The one or more induction heating elements are disposed proximate to the heat exchanger. The one or more induction heating elements are connected to a source of electrical current. When the electrical current flows through the induction heating elements, eddy currents are induced in the first metal, heating the first metal such that the fouling component sublimates, melts, absorbs, or a combination thereof into the circulating process fluid.

42 ENGINEERING↗

IMPACT OF SOIL TEMPERATURE VARIATION ON PERFORMANCE MODELING OF A NOVEL SHALLOW BORE GROUND HEAT EXCHANGER

A novel shallow bore (< 6 m deep) ground heat exchanger is proposed to substitute the conventional vertical bore ground heat exchanger (> 60 m deep) for ground source heat pump systems. A series of simulations were carried out to evaluate the impacts of the vertical soil temperature profile on the performance of the shallow bore ground heat exchanger in response to thermal loads of a ground source heat pump system, with various lengths of the shallow bore ground heat exchanger and ground thermal properties. The results indicate that the vertical soil temperature profile has a noticeable influence on the thermal response of the shallow bore ground heat exchanger. Moreover, for shallow bore ground heat exchangers with the same volume and buried depth, the one with greater length and narrower diameter has lower tank water temperature fluctuations over the year due to relatively more stable soil temperature, and the larger surface to volume ratio.

Shi, Liang↗

Material Selection and Sizing of a Thermoelectric Generator (TEG) for Power Generation in a Self-Powered Heating System

By employing the high temperature heat source to directly generate the electricity needed to power auxiliary systems in a natural gas furnace, boiler or hot water heater, a “self-powered” heating system can provide several benefits. Compared with a traditional furnace, boiler or hot water heater, when overall fuel utilization is kept constant, the self-powered system will have a higher primary energy efficiency, lower operating costs, and dramatically improved building safety and resilience during electric grid outages. Furthermore, a self-powered heating system only has a single utility connection – natural gas, without an electric connection – thus simplifying installation. A thermoelectric generator can be used for direct energy conversion of thermal energy to electricity with no moving parts, which offers a very simple means to provide power for the self-powered heating system, and the operation is without noise or vibration and can thus provide a very long system life. This paper provides an analysis focused on materials selection and the thermal power requirements for a thermoelectric generator (TEG) for use in a self-powered heating system. The dimensionless figure of merit for thermoelectric materials, zT, is used to estimate the optimal efficiency that can be achieved with a TEG to produce the electric power required in such an application. Comparisons of the predicted efficiency, the required heat transfer rate to the TEG and the heat transfer area needed for sustained operation under thermal conditions relevant to the self-powered heating application are made for several potential thermoelectric materials. This analysis was used to develop system requirements for a self-powered hot water heater using a TEG for electric power generation.

Laclair, Tim↗

Radiative Heat Transport and Optical Characterization of High Temperature Molten Salts

The goal of this project was to advance the field of molten fluoride radiative heat transfer (RHT), through optical property measurements, heat transfer loop construction and operation, and computational fluid dynamics simulations. The following outcomes have been accomplished. A comprehensive review has been conducted to compile all available RHT-relevant optical absorption data for molten fluorides. The various measurement methods have also been compiled and critiqued. Thermal emission measurement methods have been refined and documented. A unique thermal emissivity measurement facility has been constructed and used to measure the emissivity of flowing FLiBe-exposed SS316 samples. A slight increase has been observed in the emissivity compared to unexposed SS316. A dual reflectance-emission setup was partially demonstrated for the purpose of molten fluoride absorption measurement. Preliminary infrared edge data for FLiNaK was obtained. A visible near-infrared (NIR) measurement setup has been constructed and will be used to measure absorption of corrosion products in FLiBe. A new multi-band thermal radiation method using blackbody-weighted spectral bands for the absorption-coefficient was deployed to investigate the thermal performance of the UW Natural Circulation FLiBe Loop under various power levels and operating conditions. The results showed an increasing and decreasing trend in the overall heat transfer with optical thickness with a maximum at optical thickness τ D ≈Ο(1). A forced convection FLiBe loop was constructed for the purpose of studying corrosion and thermal hydraulic phenomena. A vertical cantilever pump is used to achieve up to 5 gpm and 5 m/s flow velocity in hot and cold test sections. A methodology has been established for modeling radiative heat transfer (RHT) in molten salt coolants for the purpose of quantifying the contribution of thermal radiation in conditions relevant to FHR or MSR systems. The comparison between the results obtained for forced and mixed convection showed that in the studied ranges of optical thickness, the maximum effect of RHT on overall heat transfer was 60% improvement observed at z/D = 250 for forced convection; whereas for mixed convection, that value was higher at 170% observed at z/D = 30. The highest effect of RHT on the overall energy distribution was observed at τ D ≈3.4. Negligible effect (<20%) was observed above τ D =18 and below τ D ≈0.002. A CFD code-to-code comparison was conducted using COMSOL Multiphysics at UW-Madison and STAR-CCM at MIT, for a forced and mixed convection laminar flow for a grey medium in a vertical heated using both COMSOL Multiphysics at UW-Madison and STAR-CCM at MIT. The relative error was the largest at τ D =40 for the radiative heat flux, bulk temperature, and Nusselt number. On the other hand, the relative error was the least at τ D =0.002 for the conductive heat flux, bulk temperature, and Nusselt number.

Anderson, Mark↗

Coupling subsurface and above-surface models for optimizing the design of borefields and district heating and cooling systems in the presence of varying water-table depth. In: Proceedings, 46th Workshop on Geothermal Reservoir Engineering

Dynamic energy simulation is important for the design and sizing of district heating and cooling systems with geothermal heat exchange. Current modeling approaches in building and district energy simulation tools typically consider heat conduction through the ground between boreholes, without flow of groundwater. On the other hand, detailed simulation tools for subsurface heat and mass transfer exist, but these fall short in simulating above-surface energy systems. To support the design and operation of such systems, we have developed a coupled model including a software package for building and district energy simulation, and software for detailed heat and mass transfer in the ground. For the first, we use the open-source Modelica Buildings Library, which includes dynamic simulation models for building and district energy and control systems. For the heat and mass transfer in the soil, we use the TOUGH simulator. TOUGH can model heat and multi-phase, multi-component mass transport for a variety of fluid systems, as well as chemical reactions, in fractured porous media. In previous work, we described the coupling of these software packages, including how time-dependent boundary conditions for the borehole walls are synchronized for use in Modelica and TOUGH. We verified that the coupled Modelica/TOUGH code produced consistent results with the original Modelica code for an idealized problem in which heat transfer was purely by conduction in a uniform geologic medium. Here, we examine less idealized problems for which TOUGH’s advanced capabilities for modeling fluid flow are required. The first problem has a shallow vadose zone, and the second problem has a thicker vadose zone with a water-table depth that varies in time, which requires a fine vertical grid discretization for the TOUGH model.

Doughtry, Christine↗

Initial Characterization of the Second A709 Commercial Heat

In fiscal year 2021, Idaho National Laboratory (INL) received the second commercial heat of A709 in the plate-product form, heat 529900. The chemistry, microstructure, and mechanical properties of this heat were characterized. Heat 529900 met the chemistry and mechanical property requirements specified for UNS S31025 in American Society for Testing and Materials (ASTM) A213 and American Society of Mechanical Engineers SA 213 for seamless tube which A709 was derived from. The microstructure of heat 529900 was comprised of equiaxed, recrystallized grains and elongated, unrecrystallized grains. The frequency of the unrecrystallized grains varied across the thickness of the plate with the highest frequency observed at the surface and none observed at the center. The equiaxed grain size of heat 529900 ranged from an ASTM grain size number 4 to an ASTM grain size number 6. The size of the equiaxed grains varied across the thickness of the plate with the coarsest grains located at the center of the plate. Additionally, the creep-fatigue properties of the second commercial heat were better than those of the first commercial heat.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Optimization of a Residential Air Source Heat Pump using Refrigerants with GWP <150 for Improved Performance and Reduced Emission

Using low-GWP refrigerants can reduce the Green House Gas (GHG) emission of heat pump systems. Heat exchangers and compressors are the key components and have a prominent impact on system performance, significant research is devoted to reducing the cost of the heat exchangers while achieving the same or better system performance with refrigerant charge reduction.To better understand the environmental impacts of optimized systems with low-GWP refrigerants, Life Cycle Climate Performance (LCCP) evaluation method was used to evaluate the direct and indirect emissions of the system over the course of its lifetime from manufacturing to disposal. The DOE/ORNL Heat Pump Design Model (HPDM) is used to evaluate the performance of heat pumps. Multi-objective optimizations using Particle Swarm Optimization (PSO) algorithm are performed on a 3-ton R410A residential air source heat pump on market. Seven R410A alternatives, i.e., R32, R454B, R454C, R455A, R457A, R1234yf and R1234ze(E) are investigated. The last five fluids have GWP lower than 150.As a result, 5.5%-12.8% seasonal energy efficiency ratio 2 (SEER2) improvement is achieved, and the optimized systems reduce life cycle CO2 emission by 8.5%-28.6% with GWP lower than 150 refrigerants. The optimal heat exchangers can fit into the original R410A fan-coil units; therefore, the proposed design method establishes a production and installation path to produce cost-effective low-GWP heat pumps easily accepted by end users.

Li, Zhenning↗

High Temperature Heat Pumps and Their Roles in the Decarbonization of Building and Industry

Heat pumps have been sought as a promising technology for air and water heating processes in buildings. Several OEMs have been commercializing heat pumps with varying capacities; However, the application has been limited to lower temperatures (less than 70℃). With the recently growing interest in replacing gas-fired equipment for buildings and industrial processes, a new class of heat pumps, known as high-temperature heat pumps, is gaining substantial interest where the target temperatures are higher than the conventional heat pump technology (greater than 90℃). The current study is focused on this class of heat pumps and aims to provide a holistic overview of state-of-the-art technology while highlighting major challenges and opportunities. The discussion will be focused on the availability of technology to enable higher sink temperatures, deployment-based applications, waste heat recovery, and process integration and controls.

Nawaz, Kashif↗

Experimental Evaluation of a High-Performance Cold-Climate Heat Pump Using Tandem Vapor-Injection Compressors

A high-performance cold-climate heat pump (CCHP) was developed and experimentally validated through comprehensive laboratory and field testing. The system utilized two equal-size tandem vapor-injection (VI) compressors with an inter-stage flash tank to improve efficiency and capacity retention under subfreezing conditions. Laboratory testing was conducted on a 3-ton prototype in a controlled environmental chamber equipped with calibrated thermocouples, refrigerant-side mass flow and pressure transducers, and precision airflow measurement for energy balance verification. The prototype achieved heating coefficients of performance (COPs) of 4.4 at 47 °F, 3.1 at 17 °F, and 2.0 at –13 °F, while maintaining 88% of its rated heating capacity at –13°F. These results confirm strong low-temperature performance and indicate the potential for significant reductions in electric resistance backup use. A field prototype was installed and monitored in a residential building in Fairbanks, Alaska, during a heating season. Instrumentation included real-time power, temperature, and refrigerant state measurements to evaluate performance under dynamic outdoor conditions. The heat pump operated reliably down to –30 °F, delivering 75% of its rated heating capacity with a COP of 1.8, while maintaining stable operation, effective defrost control, and indoor comfort without auxiliary heating. The combined laboratory and field results demonstrate that the tandem VI compressor configuration provides a practical and energy-efficient approach for residential heat pumps designed for cold and very cold climate regions.

Hu, Yifeng [ORNL] (ORCID:0000000242875185)↗

Investigation of heat pump technologies for high-temperature applications above 250 °C

This paper examines heat pump (HP) technologies to achieve heat supply temperatures above 250 °C, referred to as ultra-high-temperature heat pump (UHTHP). UHTHP, as a low-carbon heat delivery and heat augmentation technology, can offer an alternative to traditional combustion heating for decarbonizing high-temperature industrial processes. However, the heat supply temperature of over 250 °C surpasses the temperature range typically covered in the high-temperature HP literature and existing capabilities of commercial HP systems. This paper reviews HP technologies with the potential to evolve into UHTHP. Additionally, UHTHP studies in the literature are analyzed to compare the pros, cons, and technical potentials of various HPs using different thermodynamic cycles and fluids. Furthermore, we then pinpoint the technical gaps and challenges that have hindered widespread adoption of UHTHP in industry, explore potential improvements and solutions, and discuss the feasibility. Current efforts aim to lay the ground for future research, development, and commercial deployment for UHTHP.

32 - ENERGY CONSERVATION, CONSUMPTION, AND UTILIZA↗

Performance evaluation of a wrapped around condenser for heat pump water heater applications

In this report, accurate performance evaluation of a wrapped-around condenser for heat pump water heaters (WHPWH) is critical since the COP of the system depends heavily on thermal stratification and condenser design. An analytical, quasi-steady state heat balance method has been developed to determine the optimal spacing between adjacent channels, tube diameter, tube shape, and total refrigerant charge amount for the condenser. The heat transfer rate is compared among three approaches: the refrigerant thermodynamic model, the condenser-wrap fin model, and the analytical natural convection model on the inside of the tank for the three regions based on the refrigerant phase (e.g., super-heated, saturated, or subcooled). The heat transfer rate was predicted by a combination of slug-plug and annular flow for a D-shaped helical tube. Experimental data were used as boundary conditions for validating the model. The rate of heat transfer based on tube shape and tank wall temperatures was compared by CFD analysis. Parametric analysis indicates a tradeoff between refrigerant mass, pressure drop, tube diameter, and tube length to maximize the heat transfer rate. The model suggests the saturated region length can be extended by 400%, and the condenser pressure drop can be reduced by 23% with an optimal spacing pattern.

42 ENGINEERING↗

Dual-season thermal energy storage-integrated heat pump system for load shifting: experiments, modeling and nationwide analysis

Here, this paper proposes and validates a dual-season thermal energy storage-integrated heat pump (TES-HP) system that shifts building electric load in both cooling and heating modes using a single phase-change TES. The design uses the TES as a heat sink for the condenser in summer and a heat source for the evaporator in winter, thereby reducing on-peak electric demand while ensuring compatible with existing air-distribution systems. A 14-kW TES-HP prototype with six operating modes and novel refrigerant charge management strategies was experimentally tested under varied conditions. Subsequently, data-driven polynomial performance curves were developed and validated against experiments, then coupled with a phase change material (PCM) model and a calibrated building model within a rule-based controller. Single-day case studies demonstrated effective on-peak demand reduction while maintaining thermal comfort. During cooling, hourly power was lowered by up to 1.5 kW; in heating, average hourly power decreased from over 3.5 kW to 1.8 kW, compared to an HP-only system, achieving 64.5 % load shifting, and the need for resistance heating was eliminated. Seasonal simulations showed typical on-peak electricity savings of 25–35 % in cooling and 40–65 % in heating, with the largest benefits on the hottest and coldest days. Extended response-surface analysis and nationwide mapping quantified load shifting as functions of ambient and TES temperatures, revealing a seasonal trade-off in TES phase-change temperature. These results demonstrate the TES-HP system as a practical and scalable solution for grid-interactive buildings that reduces on-peak demand and electricity use while maintaining thermal comfort and enhancing grid flexibility and reliability.

Grid-interactive buildings↗

One piece ceramic heat exchanger for concentrating solar power electric plants

Using additive manufacturing techniques, a ceramic heat exchanger was optimized for a concentrating solar power (CSP) electric power plant with a corrosive molten salt at atmospheric pressure as the solar field heat transfer fluid and supercritical carbon dioxide at 200 bar as the power block fluid. Temperatures ranged from 750 °C to 540 °C. The plant heat exchanger was optimized for heat transfer and stress using 1 m³ modules arranged in parallel. Heat transfer was optimized using COMSOL Multiphysics software resulting in a unique semi-elliptical cross section for the fluid flow channels in a counter-flow configuration. Counter-flow was made possible through additive manufacturing of the fluid headers as part of each modular heat exchanger thus producing the entire module as a single piece and minimizing cost. Using reasonable parametric values, a heat exchanger module was optimized to 0.5 MW/m³, and a section of it was manufactured including the fluid headers. Here, parametric studies showed the potential for a module to reach 3.5 MW/m³.

14 SOLAR ENERGY↗

Modeling of Additively Manufactured Ceramic Heat Exchangers with Semi-Elliptical Cross-Section Flow Channels

An approximate and easily applied analytical model was developed for heat transfer calculations of heat exchangers consisting of multiple rows and columns of heat transfer fluid flow channels with semi-elliptical cross sections. Heat exchangers of this type are being developed by using ceramic material and additive manufacturing for high temperature and pressure-concentrating solar electric power plants. Calculations using the model require only the geometrical dimensions and flow conditions of the heat exchanger. Comparisons of modeling predictions, with both simulation results and experimental data, were conducted to verify the viability of the model. The results showed good agreement where almost all the modeling predictions were within 20% of the simulation results or the experimental data. Finally, the proposed modeling approach is more generally applicable to heat transfer analysis of heat exchangers with similar flow channel configurations to those considered in this study.

Ceramic↗

Impact of soil model complexity on the long-term thermal performance prediction of a new shallow bore ground heat exchanger

Shallow bore ground heat exchangers have been investigated in recent years because they have the potential to reduce the initial cost of the ground source heat pump system. Correctly modeling the transient heat transfer between the ground heat exchanger and the surrounding soil is essential for predicting a ground heat exchanger's performance. Simplification of the soil model could increase computation speed but sacrifice accuracy. This study investigates the impact of the soil model complexity on the annual performance prediction of a new shallow bore ground heat exchanger, the underground thermal battery (UTB). A simple 1D soil model and a more detailed 2D soil model were implemented, and they were validated against a 3D soil model. Overall, the resulting predictions of the UTB’s response from the 1D and 2D models to a given thermal load in different climates were compared. The results show that the root mean square differences between the hourly temperatures of the UTB during a year predicted using the two soil models range from 1.17°C to 3.39°C. As a result, the difference in the annual power consumption of the heat pump was between 0.7% and 3.4%. Furthermore, the dimensions of the UTB affected its performance, and a longer UTB was less sensitive to the soil models.

42 ENGINEERING↗