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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 145 records · Page 8
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Impact of Technology Improvements on the Cost of Hydrogen Produced using SOEC Technology at Large Scale

National Energy Technology Laboratory (NETL) provides system-level process, cost, and market analyses on solid oxide cell (SOC) based technologies. Specifically, techno-economic analyses (TEA), market assessments, and other technology evaluations serve to guide the U.S. Department of Energy (DOE) Office of Fossil Energy and Carbon Management (FECM) Reversible Solid Oxide Fuel Cell (R-SOFC) Program technology goals and objectives. These studies are key to describing how the technologies contribute to improving domestic energy infrastructure in a clean, efficient manner. This effort focuses on hydrogen generation technologies, which have received recent attention due to their potential role in economy-wide decarbonization. In particular, the study is part of a series of investigations at NETL that seek to understand the techno-economic impacts of including SOC technology in energy production, hydrogen production, and/or storage configurations. The objective of this study is to establish a detailed TEA to assess the effectiveness of incremental technology improvements needed for solid oxide electrolysis cell (SOEC) technology to achieve the U.S. DOE’s Hydrogen Shot goal of hydrogen production at less than $1 per kilogram. To take advantage of the benefits of economies of scale, the SOEC hydrogen facilities are sized to produce ≈250,000 metric tons of hydrogen annually with an electrolysis load of one gigawatt (direct current). Some additional critical assumptions include stacks that operate near the thermo-neutral voltage of 1.28 V to avoid adverse thermal gradients, all necessary steam and heat is generated by electric boilers and heaters to enable green hydrogen production, and an air sweep is used to control the oxygen concentration in the air electrode exhaust stream. System efficiency and levelized costs of hydrogen (LCOH) for each case are presented.

Hackett, Gregory↗
DOE OSTI2024

Field Validation of a Pilot-scale Black Liquor Membrane for Water Removal at Ahlstrom-Munksjö Paper Mill in Mosinee, WI

Project Background: The Industrial Technology Validation (ITV) program aims to identify and demonstrate the performance of new, emerging, and underutilized technologies in the industrial sector to help inform decisions towards accelerating commercialization and deployment. Pulp and paper is considered one of the most energy-intensive industries in the manufacturing sector. There are several methodologies for converting wood into pulp in the paper-making industry. The kraft process is a chemical method for producing wood pulp. The kraft process generates black liquor as a byproduct of pulp production. Traditionally, water is evaporated from the liquor by a set of multi-effect evaporators (MEEs), which concentrate weak black liquor (WBL) into strong black liquor (SBL) to support efficient combustion in a recovery boiler. Concentrating black liquor is an energy-intensive step in recovering pulping chemicals and generating high-pressure steam from dissolved wood solids. About 7% of pulp and paper energy usage, or nearly 164 trillion Btu, is used to remove water from black liquor in U.S. kraft pulp mills per year. The U.S. DOE’s IEDO is interested in the black liquor membrane technology evaluated in this report because it offers the potential for a more energy-efficient and less carbon-intensive kraft pulping process across 99 kraft pulp mills in 24 states (Agenda 2020 Technology Alliance 2016). This ITV project validates an innovative black liquor membrane technology for kraft pulp mills to understand its impact and benefits. Via Separations is a technology vendor that developed a graphene oxide membrane system to remove water from WBL before entering the evaporator set. High-pressure positive displacement (HPR) pumps move the black liquor through membranes that separate water and create a more concentrated black liquor. The vendor claims their pre-commercial technology reduces evaporator steam consumption by dewatering WBL before entering the evaporators. They also claim their technology has non-energy benefits such as enhanced soap collection and improved pulp throughput. This evaluation focuses on validating the energy and carbon dioxide (CO 2 e) emissions benefits associated with the membrane system.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2024

Field Validation of a Pilot-Scale Black Liquor Membrane for Water Removal

Pulp and paper processing is considered one of the most energy-intensive industries in the manufacturing sector. Concentrating black liquor is a particularly energy-intensive process in this industry, used to recover pulping chemicals and generate high-pressure steam from dissolved wood solids. About 7% of pulp and paper energy usage, or nearly 164 trillion British thermal units (Btu) per year, is used to remove water from black liquor in U.S. kraft mills. The U.S. Department of Energy’s Industrial Efficiency and Decarbonization Office is interested in this black liquor membrane technology because it offers the potential for a more energy-efficient and less carbon-intensive kraft pulping process. The membrane is intended to pretreat black liquor to reduce natural gas usage in evaporators that remove water from black liquor. This technology has the potential to be replicated across 99 kraft pulp mills in 24 states. This membrane technology is considered precommercial, and the demonstration was a small-scale side-stream field validation. To make an assessment on performance with a higher level of certainty, additional studies at larger scales are recommended.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS1987

Energy Recovery

The United States and other countries face the problem of waste disposal in an economical, environmentally safe manner. A widely applied solution adopted by Americans is "waste to energy," incinerating the refuse and using the steam produced by trash burning to drive an electricity producing generator. NASA's computer program PRESTO II, (Performance of Regenerative Superheated Steam Turbine Cycles), provides power engineering companies, including Blount Energy Resources Corporation of Alabama, with the ability to model such features as process steam extraction, induction and feedwater heating by external sources, peaking and high back pressure. Expansion line efficiency, exhaust loss, leakage, mechanical losses and generator losses are used to calculate the cycle heat rate. The generator output program is sufficiently precise that it can be used to verify performance quoted in turbine generator supplier's proposals.

Source record↗
NASA NTRS1976

Liquid-metal magnetohydrodynamic system evaluation

The present study emphasizes a direct coal-fired design using a bubbly two-component flow of sodium and argon in the MHD generator and a Rankine steam-bottoming plant. Two basic cycles were studied, corresponding to argon temperatures of 922 and 1089 K at the duct inlet. The MHD duct system consisted of multiple ducts arranged in clusters and separated by iron magnet pole pieces. The ducts, each with an output of about 100 MW, were parallel to the flow, but were connected in series electrically to provide a higher MHD voltage. With channel efficiencies of 80%, a pump efficiency of 90%, and a 45% efficient steam-bottoming plant, the overall efficiency of the 1089 K liquid-metal MHD power plant was 43%.

Holman, R. R.↗
NASA NTRS1981

Parametric study of potential early commercial MHD power plants. Task 3: Parameter variation of plant size

Plants with a nominal output of 200 and 500 MWe and conforming to the same design configuration as the Task II plant were investigated. This information is intended to permit an assessment of the competitiveness of first generation MHD/steam plants with conventional steam plants over the range of 200 to 1000 MWe. The results show that net plant efficiency of the MHD plant is significantly higher than a conventional steam plant of corresponding size. The cost of electricity is also less for the MHD plant over the entire plant size range. As expected, the cost differential is higher for the larger plant and decreases with plant size. Even at the 200 MWe capacity, however, the differential in COE between the MHD plant and the conventional plant is sufficient attractive to warrant serious consideration. Escalating fuel costs will enhance the competitive position of MHD plants because they can utilize the fuel more efficiently than conventional steam plants.

Hals, F. A.↗
NASA NTRS1981

Steam Turbines

Turbonetics Energy, Inc.'s steam turbines are used as power generating systems in the oil and gas, chemical, pharmaceuticals, metals and mining, and pulp and paper industries. The Turbonetics line benefited from use of NASA research data on radial inflow steam turbines and from company contact with personnel of Lewis Research Center, also use of Lewis-developed computer programs to determine performance characteristics of turbines.

Source record↗
NASA NTRS2015

In-Space Propulsion, Logistics Reduction, and Evaluation of Steam Reformer Kinetics: Problems and Prospects

Human space missions generate waste materials. A 70-kg crewmember creates a waste stream of 1 kg per day, and a four-person crew on a deep space habitat for a 400+ day mission would create over 1600 kg of waste. Converted into methane, the carbon could be used as a fuel for propulsion or power. The NASA Advanced Exploration Systems (AES) Logistics Reduction and Repurposing (LRR) project is investing in space resource utilization with an emphasis on repurposing logistics materials for useful purposes and has selected steam reforming among many different competitive processes as the preferred method for repurposing organic waste into methane. Already demonstrated at the relevant processing rate of 5.4 kg of waste per day, high temperature oxygenated steam consumes waste and produces carbon dioxide, carbon monoxide, and hydrogen which can then be converted into methane catalytically. However, the steam reforming process has not been studied in microgravity. Data are critically needed to understand the mechanisms that allow use of steam reforming in a reduced gravity environment. This paper reviews the relevant literature, identifies gravity-dependent mechanisms within the steam gasification process, and describes an innovative experiment to acquire the crucial kinetic information in a small-scale reactor specifically designed to operate within the requirements of a reduced gravity aircraft flight. The experiment will determine if the steam reformer process is mass-transport limited, and if so, what level of forced convection will be needed to obtain performance comparable to that in 1-g.

Logistics↗
DOE OSTI2025

High-Temperature Active Magnetic Bearing Development for Supercritical CO 2 Machinery Applications

Hermetic machinery utilizing gas bearings for MW-scale supercritical CO 2 (sCO 2 ) machinery applications can have significantly lower power loss and enable improved cycle efficiency compared to conventional machinery with oil-lubricated bearings. Active magnetic bearings (AMBs) are another option anticipated to have similar power loss and load capacity to gas bearings as well as offering larger mechanical tolerances, the ability to tune properties, and high reliability due to lack of mechanical wear. AMBs also have proven commercial experience at MW-scale, though environments for high-temperature sCO 2 power cycle machinery conditions are novel. Besides the potential impact of AMBs for sCO 2 turbomachinery, the technology also offers promising benefits for steam and gas turbines for power generation, compressors and expanders for industrial heat and power, and in other oil and gas and space applications. The goals of this project were to conceptual design an AMB and perform material testing. Conceptual designs for radial and thrust AMBs were produced based on a hermetically-sealed sCO 2 machinery waste-heat recovery (WHR) application for sizing and loads, and choosing a target design temperature of 540°C useful for high-temperature sCO 2 turbines for concentrating solar power (CSP) applications. Conceptual designs were initially developed for multiple radial and thrust AMBs with spreadsheet-based calculations before selecting one of each to develop further using higher-fidelity design methods for magnetic and structural performance. It was found that the radial AMB at 540°C was feasible, but the thrust AMB needed to be limited to 315°C for high-speed operation. The decision for a reduced-temperature thrust AMB was the result of several significant conclusions: 1) Hiperco 50A, originally chosen for good magnetic performance at high temperature, had insufficient strength for high-speed operation, so it was replaced with 17-4 PH. 2) The reduced magnetic performance from 17-4 PH yielded a larger bearing size, reducing the strength margin. 3) This ultimately led to a creative design implementing a more-compact E-core topology, compared to the original (conventional) C-core, and an integral shaft-disk with Hirth joint connection. These conceptual designs are unique for the size and temperature in CO 2 , relevant for MW-scale CSP applications. Long term, high temperature test data was generated for several materials, filling a void in the current body of literature. Corrosion and magnetic performance measurements were produced for PM materials (Alnico 5-7C, Alnico 9C, and SmCo) with and without nickel-coating for environments of high-temperature CO 2 up to 550°C at atmospheric pressure and 450°C at 103 bar for up to 6,000 hours. Corrosion measurements were also produced for Hiperco 50, a SM material relevant for AMB laminations, with and without C5 coating. Comparisons were also made for 450°C and 550°C, atmospheric pressure air exposures up to 5,000 hours. Results generally show that coatings can be effective at improving oxidation resistance of the bare materials, and Alnicos generally outperformed SmCo after high-temperature exposure. In addition to technical feasibility demonstrated by the design, economic feasibility was demonstrated by updating the TEA from the reference machine, re-evaluating it with CAPEX and OPEX to reflect estimated changes from process-lubricated bearings to AMBs. AMBs were shown to be comparable in performance to process-lubricated bearings, still showing a notable improvement over conventional machinery architecture with oil-lubricated bearings.

42 ENGINEERING↗
NASA NTRS1978

Applications of thermal energy storage to process heat and waste heat recovery in the iron and steel industry

The system identified operates from the primary arc furnace evacuation system as a heat source. Energy from the fume stream is stored as sensible energy in a solid medium (packed bed). A steam-driven turbine is arranged to generate power for peak shaving. A parametric design approach is presented since the overall system design, at optimum payback is strongly dependent upon the nature of the electric pricing structure. The scope of the project was limited to consideration of available technology so that industry-wide application could be achieved by 1985. A search of the literature, coupled with interviews with representatives of major steel producers, served as the means whereby the techniques and technologies indicated for the specific site are extrapolated to the industry as a whole and to the 1985 time frame. The conclusion of the study is that by 1985, a national yearly savings of 1.9 million barrels of oil could be realized through recovery of waste heat from primary arc furnace fume gases on an industry-wide basis. Economic studies indicate that the proposed system has a plant payback time of approximately 5 years.

Katter, L. B.↗
NASA NTRS1980

The JPL parabolic dish project

The parabolic dish solar collector is a highly versatile concentrating collector system that can produce heat for many thermal processes and electricity by coupling the collector to a suitable heat engine. This paper discusses a project for the development of these collector systems and summarizes contracts with industry for developing the dish subsystems which include concentrator, receiver, and heat engine. An early market for dishes is the dispersed small community market which depends heavily on oil to operate diesel or steam turbine plants in order to generate electricity. The present contracts with industry for conducting engineering experiments using the developed dish hardware to demonstrate the technology in these early opportunity markets is also discussed.

Truscello, V. C.↗
NASA NTRS1976

Study of the application of solar chemical dehumidification system to wind tunnel facilities of NASA Lewis Research Center at Cleveland, Ohio

Energy utilization and cost payback analyses were prepared for proposed modifications. A 50,000 CFM standard compact packaged solid desiccant dehumidifier utilizing high temperature hot water (HTHW) for desiccant regeneration was added. The HTHW is generated by utilizing solar energy and is stored in a storage tank. A steam boiler is provided as a back-up for the solar system. A 50,000 CFM standard compact package solid desiccant dehumidifier utilizing high temperature hot water (HTHW) for desiccant regeneration was added. The HTHW is generated by utilizing a steam boiler and a heat exchanger and is stored in a storage tank.

Source record↗
NASA NTRS1979

A 15kWe (nominal) solar thermal electric power conversion concept definition study: Steam Rankine reheat reciprocator system

An evaluation was made of the potential of a steam Rankine reheat reciprocator engine to operate at high efficiency in a point-focusing distributed receiver solar thermal-electric power system. The scope of the study included the engine system and electric generator; not included was the solar collector/mirror or the steam generator/receiver. A parametric analysis of steam conditions was completed leading to the selection of 973 K 12.1 MPa as the steam temperature/pressure for a conceptual design. A conceptual design was completed for a two cylinder/ opposed engine operating at 1800 rpm directly coupled to a commercially available induction generator. A unique part of the expander design is the use of carbon/graphite piston rings to eliminate the need for using oil as an upper cylinder lubricant. The evaluation included a system weight estimate of 230 kg at the mirror focal point with the condenser mounted separately on the ground. The estimated cost of the overall system is $1932 or $90/kW for the maximum 26 kW output.

Fuller, H.↗
DOE OSTI2024

Integration of IH 2 ® with Cool Reformer for the Conversion of Cellulosic Biomass to Drop In Fuels

GTI Energy has integrated the Cool Reformer technology with the IH 2® -50 pilot plant (which can process a maximum of 50kg/day of biomass feed) to demonstrate the suitability of this new reforming technology for producing hydrogen within IH 2 ® process. As part of this study, we showed that all of the hydrogen required for the IH 2® process could be produced from steam reforming the IH 2® light gas generated within the process and the system can be integrated in a cost-effective way compared to the use of standard SMRs.

08 HYDROGEN↗
NASA NTRS1981

The small community solar thermal power experiment

Contractors were asked to develop a preferred system concept, to perform sensitivity analyses, and to outline recommended approaches for the follow-on design program of a one-megawatt solar thermal demonstration plant. The systems recommended by the contractors in each of the categories were: (1) McDonnell-Douglas Astronautics Company: Central tower with field of south-facing heliostats; (2) General Electric Company: Field of parabolic dishes with steam piped to a central turbine-generator unit; and (3) Ford Aerospace and Communications Corporation: Field of parabolic dishes with a Stirling cycle engine/generator unit at the focus of each dish. A description of each of the proposed experimental plants is given.

Kiceniuk, T.↗
DOE OSTI2025

Numerical simulation for the design of induction heating based radio frequency reactor for ethylene production

Ethylene is a vital petrochemical compound produced in vast amounts yearly by manufacturers that have enough scale to overcome the inherent thermodynamic inefficiencies of the process. In order to address the inefficiencies that prevent smaller scale or intermittent production ethylene, investigation of new production methods are required. In this work, we investigate the use of a radio frequency (RF) based reactor system that generates heat internally as opposed to applying heat externally via steam or direct combustion of fossil fuels. In order to guide the design of an electromagnetic based reactor system, we have created a macroscale model capable of capturing heat generation at the susceptors from a produced electromagnetic field and subsequent chemical reactions. Several susceptor and induction coil designs were investigated to better understand the performance of the system.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
NASA NTRS1979

A 15 kWe (nominal) solar thermal-electric power conversion concept definition study: Steam Rankin reciprocator system

A conceptual design of a 3600 rpm reciprocation expander was developed for maximum thermal input power of 80 kW. The conceptual design covered two engine configurations; a single cylinder design for simple cycle operation and a two cylinder design for reheat cycle operation. The reheat expander contains a high pressure cylinder and a low pressure cylinder with steam being reheated to the initial inlet temperature after expansion in the high pressure cylinder. Power generation is accomplished with a three-phase induction motor coupled directly to the expander and connected electrically to the public utility power grid. The expander, generator, water pump and control system weigh 297 kg and are dish mounted. The steam condenser, water tank and accessory pumps are ground based. Maximum heat engine efficiency is 33 percent: maximum power conversion efficiency is 30 percent. Total cost is $3,307 or $138 per kW of maximum output power.

Wingenback, W.↗