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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 163 records · Page 9
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Advanced Ceramic Membranes/Modules for Ultra Efficient Hydrogen (H2) Production/Carbon Dioxide (CO2) Capture for Coal-Based Polygeneration Plants: Fabrication, Testing and CFD Modeling

Inorganic membrane-based systems are a promising technology for precombustion CO2 capture with simultaneous H2 production. State-of-the-art packages for high temperature and pressure service consist of multiple tube membrane bundles prepared in a "candle filter" configuration, in which the membrane tubes are open at one end and sealed at the other. This configuration is used for practical reasons, specifically the need to minimize problems due to thermal expansion mismatch between the ceramic tube bundle and the steel housing. However, the primary technical problem with the candle filter format for commercial-scale installations is the inability to purge the tube side (typically the permeate side), a feature that is crucial for high H2 recovery. In this study, the focus is to design and fabricate the first dual-end open full ceramic multiple tube membrane bundle that enables tube side (permeate) purge for gas separation applications. An additional key feature of this design is the simplified module layout, as the membrane bundles can be installed end-to-end with tube side (permeate) flow directly from one bundle to the next. This layout simplifies the membrane to housing seals and yields significant improvement in membrane packing density. Detailed focus areas in our studies include: (i) Materials development and preparation of the tube-to-tube sheet potting for the dual-ended bundle; (ii) the sealing and optimal module configuration design to minimize membrane stress upon module mounting; (iii) the demonstration, via the fabrication of CMS and Pd-alloy membranes supported on full-size, dual-ended ceramic support bundles, of the first example of a purgeable ceramic membrane and module; and (iv) development of a CFD model of the membrane module for calculation of feed flow distribution, and for use in scale-up, and capital cost estimating. The CFD model was validated using experimental data with the multi-tubular membrane system, employing He/N2 as a model gas mixture (surrogate for H2/CO2), and has been shown to be quite accurate. Employing the model, we are able to study the effects of operating pressure and temperature, feed and sweep gas flow rates, and the choice of membrane tube configuration on system performance.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2021

The evolution of seafloor venting from hydrate-sealed gas reservoirs

Here we use 3D seismic data to show that three rows of seafloor gas mounds can be traced downward to leak points that lie at the hydrate-gas contact within three individual dipping coarse-grained sand bodies in the Terrebonne Basin, Walker Ridge block 313, northern Gulf of Mexico. We predict the overpressure within the sand bodies by assuming that the gas pressure at the vent points equal the least principal stress. We interpret that free gas accumulates at the base of the hydrate stability zone, trapped by the overlying sand which has a high methane hydrate saturation. The free gas accumulates until the gas pressure at the base of the hydrate stability zone reaches the least principal stress in the overlying mudrock, whereupon hydraulic fractures form and fluids are vented to the surface. The warm rising fluids and perhaps localized exothermic formation of hydrate raise the local salinity and temperature. This process progressively shifts the base of the hydrate stability zone to shallower depths and dissociates the hydrate seal within the sand, which creates new leak points and results in the observed migration of the seafloor vents. Within the southwest corner of the Terrebonne Basin, this process has repeated multiple times within the Blue, Orange, and Green sands. Here this study shows how the hydrate stability zone can influence the location of fluid expulsion and in turn be affected by the warm, rising, saline fluids sealed by hydrate.

58 GEOSCIENCES↗
DOE OSTI2023

Glass Additive and Subtractive Manufacturing of a Fiber Optic Rotary Encoder for Downhole Pressure Sensing

This article presents a fiber optic rotary encoder-based pressure sensor for downhole applications. The rotary encoder, which is composed of an encoding pad and an all-glass optical fiber sensing head, converts the rotation angles of a pressure transducer to digital codes. The optical fiber only serves as the telemetry channel to directly transmit the data in digital format such that the environmental temperature influence and the long-time drift are minimized. The glass additive and subtractive manufacturing (ASM) techniques are used to embed the multichannel optical fibers into a bulk-fused silica glass substrate. Because the fused silica glass shares a similar material property to the optical fiber (e.g., thermal expansion coefficient), the optical fiber sensing head is well sealed and fixed even at an elevated temperature. The picosecond laser blackening technique is used to fabricate the high reflectivity contrast encoding pad with high accuracy. Here, the proposed pressure sensor was manufactured and experimentally verified to have a signal-to-noise ratio (SNR) of 23 dB and a linear pressure response with a root-mean-square error (RMSE) of 0.37. During the 400-h 250 °C long-term stability test, there was no digital code variation. In addition, a mathematical model to study the relationships between the sensor’s performances and design parameters was established. According to the model, a 12-bit encoder (0.02% pressure sensitivity) can be achieved with a radius of 20 mm.

02 PETROLEUM↗
DOE OSTI2024

Novel Full-Ceramic Multi-Tubular Membrane Systems for Pre-Combustion CO2 Capture with Simultaneous H2 Production: Fabrication, Performance Testing, and 3D CFD Modeling

Inorganic membranes show promise for application in pre-combustion CO2 capture with simultaneous H2 production. State-of-the-art systems for use under high temperature and pressure conditions consist of multiple membrane tube bundles prepared in a "candle-filter" configuration, in which the membrane tubes are open at one end and sealed at the other. This configuration is used for practical reasons, specifically the need to minimize potential problems due to thermal expansion mismatch, at high temperatures, between the ceramic tube bundle and the steel housing. The primary technical problem with the candle-filter configuration for use in commercial-scale installations is the inability to purge the permeate side (typically the tube side), a feature that is crucial for high H2 recovery. In this study, we fabricated dual-end open, commercial-size ceramic multiple-tube bundles made of zeolite, palladium (Pd), and carbon molecular sieve (CMS) membranes that enable permeate-side (tube-side) purge for gas separation applications. Experimental gas separation data with these membrane bundles under harsh operating conditions (temperatures up to 350 and pressures up to 800 psig), to be presented at the meeting, manifest excellent performance. Parallel to the membrane bundle construction and testing efforts, we have also developed a detailed 3D CFD modeling package using COMSOL Multiphysics software to gain more insight into the effect on the H2 purity and recovery of the detailed geometry of the multi-tubular membrane system, including the number of tubes used, their dimensions, and placement in the bundle, as well as the number, type, and positioning of internal baffles and other flow-enhancement accessories. The CFD package is validated with experimental data from different systems (1-tube, 3-tube, and 19-tube bundles), and shows high accuracy in predicting the experimental results (<5 % error in all cases). The results of our study show that the detailed internal geometry of these multi-tubular membrane systems has a considerable impact on the performance of the system as the flow maldistribution within the shell-side can substantially decrease (>40%) the H2 recovery.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2022

The Cypress Sandstone Seal System

The Cypress Sandstone is the youngest and shallowest unit in the Illinois Basin that was featured in the United States Carbon Utilization and Storage Atlas IV as a target for saline carbon storage with an estimated 0.2 to 2.3 GT of storage potential. Additional research on a residual oil zone (ROZ) developed within the Cypress Sandstone has delineated 27 prospects with approximately 290.8 million m3 (1.8 billion barrels) of oil in place. 21 to 31 million m 3 (144 to 196 million barrels) of oil is estimated to be recoverable using carbon dioxide enhanced oil recovery (CO 2 -EOR). Storage of CO 2 associated with EOR in these ROZ prospects alone, not accounting for associated main pay zones (MPZs), underlying brine formation, or intervals adjacent to or between prospects, is estimated to be up to 10.4 billion tonnes. The Cypress Sandstone is thus well understood to be a CO 2 injection target, both for EOR and associated storage. However, the seal system overlying the Cypress Sandstone is poorly understood. Unlike deeper formations such as the Mt. Simon Sandstone or the St. Peter Sandstone which are either in use as a CO 2 sink or being characterized for prospective storage, respectively, the Cypress is not overlain by hundreds of feet of impermeable shale. Rather, the Cypress is overlain by a lithologically variable interval that is composed generally of shales and limestones with some sandstone in the part of the Basin where the Cypress is deep enough to facilitate CO 2 storage. Also, due to its status as one of the shallowest and most prolific oil reservoirs in the Basin, the seal system overlying the Cypress Sandstone has a relatively high number of legacy well penetrations. The purpose of this report is to characterize the Cypress Sandstone seal system using well logs and available core. Gross thickness, lithology (facies), and mineralogy of seals is described and mapped across the Basin. The column height of CO 2 that can be held is calculated using capillary pressure data from a representative core.

02 PETROLEUM↗
DOE OSTI2021

Field-scale fault reactivation experiments by fluid injection highlight aseismic leakage in caprock analogs: Implications for CO 2 sequestration

Observations on tens-of-meter scale experiments of fault activation by fluid injection conducted in shales allow exploring how aseismic and seismic events may jeopardize the integrity of a sealing caprock overlying a CO 2 sequestration reservoir. We contrast the behavior of shale faults with another set of experiments conducted in carbonates. Significant fluid leakage occurs along the initially low-permeability shale faults when rupture is activated. Most of the leakage pathway closes when fluid injection ceases and fluid pressure drops. Dilatant slip on the fault plane alone does not explain the observed leakage behavior, which is also caused by fault opening favored by the softness of the shale, and by the structure of the fault zone that prevents fluids from diffusing into the adjacent damage zone. Experiments show a large amount of aseismic deformation. Small-magnitude seismicity (M w < -2.5) is observed outside the pressurized leakage patch. Stress transferred from this aseismic deformation patch can build up to stress-criticality and favor seismicity. Thus, in terms of fault activation in caprocks, aseismic fault slip leading to increased permeability and a loss of seal integrity is of great concern.

58 GEOSCIENCES↗
DOE OSTI2020

Real Time 3D Observations of Portland Cement Carbonation at CO2 Storage Conditions

Depleted oil reservoirs are considered a viable solution to the global challenge of CO 2 storage. A key concern is whether the wells can be suitably sealed with cement to hinder the escape of CO 2 . Under reservoir conditions, CO 2 is in its supercritical state, and the high pressures and temperatures involved make real-time microscopic observations of cement degradation experimentally challenging. Here, we present an in situ 3D dynamic X-ray micro computed tomography (μ-CT) study of well cement carbonation at realistic reservoir stress, pore-pressure, and temperature conditions. The high-resolution time-lapse 3D images allow monitoring the progress of reaction fronts in Portland cement, including density changes, sample deformation, and mineral precipitation and dissolution. By switching between flow and nonflow conditions of CO 2 -saturated water through cement, we were able to delineate regimes dominated by calcium carbonate precipitation and dissolution. For the first time, we demonstrate experimentally the impact of the flow history on CO 2 leakage risk for cement plugging. In-situ μ-CT experiments combined with geochemical modeling provide unique insight into the interactions between CO 2 and cement, potentially helping in assessing the risks of CO 2 storage in geological reservoirs.

58 GEOSCIENCES↗
DOE OSTI2020

Structural Implications of Interfacial Hydrogen Bonding in Hydrated Wyoming-Montmorillonite Clay

Montmorillonite (MMT) clay - a layered porous nanomaterial used as seals in engineered waste containment barriers for spent nuclear fuel - adopts discrete hydration/swelling states depending upon surrounding water and ion activities and confining pressure. The structure of nanoconfined water and charge-balancing counterions in the clay mineral interlayers dictate the swelling and mechanical behavior of MMT, so a molecular model for this clay with high structural fidelity is required to accurately predict the reliability of long-term nuclear waste storage. Here, we present a molecular model for MMT that is based on high resolution transmission electron microscopy of Wyoming-MMT single crystals. Imaging data unambiguously show a cis-vacant arrangement of structural hydroxyl groups in the octahedral sheet, whereas existing molecular models assume a centrosymmetric trans-vacant configuration for MMT. Furthermore, using atomistic simulations, we find that the cis-vacant arrangement of structural hydroxyl groups significantly affects the structure of adsorbed water yielding a larger population of hydrogen bonds with bridging oxygens on the tetrahedral sheet and weak hydrogen bonding between the hydroxyl groups in the octahedral sheet and water in the clay mineral interlayers. As a result, water adsorbed in the interlayer is more "ice-like", with stronger ordering and lower density, although the diffusivity of the interlayer species is not significantly diminished. Our improved structural model for MMT provides insight into the energetics of water adsorption, which ultimately dictates its pore- to macro-scale swelling, transport, and fracture properties.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

The design of a photoionization front experiment using the Z-Machine as a driving source and estimated measurements

Radiation-driven heat fronts are present in the early universe during reionization, the circumstellar medium of supernovae, and in high-energy-density physics experiments. Dedicated experiments to observe and diagnose the behavior of these types of heat fronts can improve our understanding of these phenomena. A simulation study of photoionization fronts using the HELIOS-CR radiation hydrodynamics code provides an experimental design for the Z-Machine at Sandia National Laboratory using a measurement-calibrated input radiation flux to drive the photoionization front. The simulations use detailed atomic physics and non-diffusive radiation transport in 1D to determine an optimal gas pressure of 0.75 atm for an experiment in N gas as well as the effects of increasing the thickness of the window that seals the gas cell. Post-processing of these simulations demonstrates that ratios of atomic rate coefficients place the heat front in a physics regime where photoionization dominates the energy deposition. Here, to see the sensitivity of the simulations to changes in the model and spatial grid, this analysis performed resolution, atomic model detail, and radiation transport angular grid studies showing less than 10% deviation from the nominal model for increased complexity, when possible. An effort to emulate 3D geometric effects on the radiation flux using an artificial attenuation scheme has shown that, even for conservative estimates of the flux, simulations still produce a photoionization front. Estimations of a streaked, visible spectroscopy measurement using SPECT3D showed that line emission measurements are present early in time and that later in time thermal emission should become dominant.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Additively Manufactured Tamper Evident Container

Los Alamos National Laboratory has developed a revolutionary and reliable new tamper evident container (TEC) to monitor and protect the health, security, and distribution of high-value assets, technological advancements, products, materials and more that are critical to the operations of businesses and government organizations. Unlike traditional tamper evident seals, the entire TEC serves as a seal, with encrypted on-board electronics able to continuously monitor and log structural health data including but not limited to force, temperature, pressure, humidity, orientation, radiation, acceleration, or vibration as needed. Analog and encrypted digital boards safely stored inside the TEC permanently record the complete integrity history of the protected items and have the ability to alert the TEC owners or take immediate defensive actions should a disruptive or tamper event take place.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Radiation Hardened Foam Cold Test Plan - Phase II: Foam Characterization Testing and Environmental Chamber Testing of FoamBag Fixative Foam

This document outlines the Phase II test objectives and implementation plan for a down-select foam fixative technology intended to facilitate activities in support of the Savannah River Site (SRS) F/H labs deactivation and decommissioning (D&D) efforts. It is a collaborative effort between Savannah River National Laboratory (SRNL), Florida International University (FIU), and the SRS F/H labs team intended to test and evaluate the potential of a polyurethane resin foam in mitigating the release of contamination during dismantling operations on radioactively contaminated piping in legacy facilities. The cold test plan addresses specific requirements highlighted by site and safety personnel and will be executed at FIU and SRNL test and lab facilities. Results from the cold tests will inform the hot test at F/H labs, which will use the foam fixative to confine and/or isolate residual contamination within a 3-dimensional void space of Hastelloy C-22 piping designated for removal from the area and transported to a designated disposal facility. Phase I testing was previously conducted using Hilti CP620 fixative foam. Results from Phase I testing indicate Hilti CP-620 fixative foam is incompatible with SRS site hot taps as an effective foam delivery method into Hastelloy C-22 piping. Phase II testing will be conducted using FoamBag TM fixative foam as an alternative fixative foam option. Phase II testing will address eight test objectives: (1) evaluation of the adhesion and bonding properties of FoamBag TM in Hastelloy C-22 piping, (2) evaluation of the adhesion of FoamBag TM in piping under various moisture conditions, (3) determination of the heat profile of FoamBag TM during curing, (4) determination of the internal pipe pressure after FoamBag TM deployment and curing, (5) conduct a leak test to determine if FoamBag TM is effective at creating a full seal within piping, (6) headspace testing of FoamBag TM to determine if there are any associated off-gas hazards during FoamBag TM curing, (7) conduct environmental chamber testing of FoamBag TM to understand how environmental parameters impacts FoamBag TM curing, and (8) conduct fire testing to evaluate FoamBag TM fire retardant characteristics.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Improved Creep Testing Approach for Bentonite EBS

In the United States, the nuclear reactor contributes 18.7 percent of the nation’s total electricity generation and produces a significant amount of spent nuclear fuel (SNF) and high-level waste. Because SNF is being stored for longer periods than initially envisioned, the U.S. Department of Energy Office of Nuclear Energy, Office of Spent Fuel and Waste Science and Technology is assessing the technical performance of the SNF storage systems after extended durations. The concept of a sustainable geologic repository for SNF disposal relies heavily on the safety provided by multiple barriers, such as repository host rock, overlying rock formation, and human-made engineered barrier systems (EBS). One of the major components of EBS is bentonite-based buffer materials that isolate the nuclear-waste canisters from the host rock and fill the void left in the horizontally drilled boreholes. The resaturated bentonite has a swelling characteristic, which is useful for self-sealing the microcracks in the host rock and supporting the canister’s heavy weight. However, factors such as nonuniformity in the saturation, swelling pressure of bentonite, and the high temperature at the canister-bentonite interface may lead to instability of the waste canister inside the borehole. Therefore, evaluating the long-term deformation of bentonite-based material is necessary. RESPEC Company, LLC recently completed a preliminary study for the U.S. Department of Energy (DE SC0022804) that is attempting to understand the time-dependent deformation in the consolidated sand/bentonite (SB) specimens through triaxial creep experiments and improve the understanding of EBS performance under anticipated repository conditions. The project included developing a standard testing procedure for preparing the consolidated core specimen from a mixture of sand and bentonite in a 50:50 ratio by weight, fabricating a new pressure vessel in-house, modifying existing creep equipment to perform triaxial creep experiments on consolidated SB specimens, and performing six long-term triaxial creep experiments under low-deviatoric stress at two different temperature conditions, which is representative of hypothetical conditions that might be encountered in a geologic repository within a reasonable rate of success in completing creep experiments. The consolidated SB specimen was prepared using the novel specimen preparation procedure and had physical characteristics (e.g., moisture content and bulk density) reasonably comparable with the properties of bentonite-based buffer, which is proposed to be used in the EBS in the Swedish KBS-3H design and the Swiss design of SNF disposal in the horizontal drifts. The newly fabricated pressure vessel could withstand the confining pressure of up to 15 megapascals (MPa) while maintaining the test temperature of up to 90 degrees Celsius (°C) for long-term creep experiments. The preliminary results from the triaxial creep experiments suggested that the consolidated SB specimen may experience time-dependent deformation at a low-deviatoric stress state and room temperature condition. Based on the deformation recorded in the SB specimen from axial and radial linear variable differential transformers (LVDTs) and physical characteristic changes, it is apparent that the time-dependent deformation is a combination of consolidation and creep, which is influenced by the level of deviatoric stresses and temperature. The systematic creep testing of bentonite-based specimens helped develop a standard testing procedure applicable for analyzing the similar characteristics of shale or clay-like materials in different geologic conditions outside repository science, including in civil engineering and infrastructure projects, underground and open pit mining, and deep drilling.

58 GEOSCIENCES↗
DOE OSTI2021

Risk-based area of review estimation in overpressured reservoirs to support injection well storage facility permit requirements for CO 2 storage projects

This paper by the Energy & Environmental Research Center presents a workflow and modeling approach for delineating a risk-based area of review (AOR) to support a U.S. Environmental Protection Agency (EPA) Class VI permit for a carbon dioxide (CO 2 ) storage project. The approach combines semianalytical solutions for estimating formation fluid leakage through a hypothetical leaky wellbore with the results of numerical reservoir simulations to define the AOR. The modeling utilizes 1) semianalytical solutions from the peer-reviewed literature for formation fluid leakage through abandoned wellbores by Raven (1990) and Avci (1994), 2) a FORTRAN model compiled and described in Cihan et al. (2011, 2012) called ASLMA (Analytical Solution for Leakage in Multilayered Aquifers), and 3) a computational framework for estimating a risk-based AOR first proposed by Oldenburg et al. (2014, 2016). Therefore, the approach builds upon well-established research and underlying hydrogeological principles that have been upheld for nearly three decades. Moreover, the ASLMA model has been broadly applied to an array of storage projects. The work presented herein extends these earlier works using a custom wrapper written in the software environment, R (R Core Team, 2020), which was developed to perform multiple runs of the ASLMA model using given ranges for one or more input parameters. In addition, the current work simulates the pressure buildup within the storage reservoir in response to CO 2 injection using a compositional simulator to better accommodate the temporospatial evolution of pressure buildup within the storage reservoir that is more accurately modeled using a heterogeneous geologic model and a compositional simulator that accounts for the multiphase interactions. The workflow is demonstrated using a case study for a 180,000-metric-ton-per-year storage project located in the PCOR (Plains CO 2 Reduction) Partnership region. For the storage project evaluated here, under the scenario where the leaky wellbore is open to a saline aquifer (thief zone) between the overlying seal (cap rock) and the underground sources of drinking water (USDW), the risk-based AOR essentially collapses to the areal extent of the CO 2 plume in the storage reservoir because the pressure buildup in the storage reservoir beyond the CO 2 plume is insufficient to drive formation fluids up a hypothetical leaky wellbore into the USDW. However, even under the conservative assumption that the leaky wellbore is not open to a thief zone, beyond the areal extent of the CO 2 plume, the incremental leakage is less than 400 m 3 over 20 years, which represents ~0.0001% or less of the total volume of water contained within the USDW rock volume. As discussed in the text, the threshold criterion for defining the risk-based AOR is site-specific and should be informed by the results of the sensitivity analysis and available site characterization data. The approach outlined in this paper is designed to be protective of USDWs and, therefore, comply with the Safe Drinking Water Act requirements and provisions for the U.S. EPA Class VI Underground Injection Control (UIC) Program (Class VI Rule) and North Dakota Administrative Code Chapter 43-05-01.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2020

Normal or abnormal? Machine learning for the leakage detection in carbon sequestration projects using pressure field data

The international commitments for atmospheric carbon reduction will require a rapid increase in carbon capture and storage (CCS) projects. The key to any successful CCS project lies in the long term storage and prevention of leakage of stored carbon dioxide (CO 2 ). In addition to being a greenhouse gas, CO 2 leaks reaching the surface can accumulate in low-lying areas resulting in a serious health risk. Among several alternatives, some of the more promising CCS storage formations are depleted oil and gas reservoirs, where the reservoirs had good geological seals prior to hydrocarbon extraction. With more CCS wells coming online, it is imperative to implement permanent, automated monitoring tools. We apply machine learning models to automate the leakage detection process in carbon storage reservoirs using rates of (CO 2 ) injection and pressure data measured by simple harmonic pulse testing (HPT). To validate the feasibility of this machine learning based workflow, we use data from HPT experiments carried out in the Cranfield oil field, Mississippi, USA. The data consist of a series of pulse tests conducted with baseline parameters and with an artificially introduced leak. Here, in this study, we pose the leakage detection task as an anomaly detection problem where deviation from the predicted behavior indicates leaks in the reservoir. Results show that different machine learning architectures such as multi-layer feed forward network, Long Short-Term Memory, and convolutional neural network are able to identify leakages and can provide early warning. These warnings can then be used to take remedial measures.

58 GEOSCIENCES↗
DOE OSTI2021

Advanced Multi-Tube Mixer Combustion for 65% Efficiency (Final Report)

This project targeted advanced low NOx combustion for advanced gas turbines capable of 65%, or greater, efficiency in combined cycle application. This technology advancement has further potential to benefit gas turbines used in coal based IGCC applications with pre-combustion carbon capture and hydrogen as the resulting fuel. The program developed and synthesized the most advanced combustion system capable of achieving low NOX emissions up to turbine inlet temperatures of 3100F while also supporting the load-following needs of a modern grid. The combustion system contributes to the overall gas turbine efficiency goal by setting the maximum cycle temperature achievable for a given NOX level and by minimizing the through-combustor air flow pressure drop. Focus areas for this project targeted maximizing the turbine inlet temperature entitlement, as constrained by emissions considerations. The design also minimized parasitic air flow pressure drop by using advanced cooling techniques and performance materials selections and by minimizing hot surface area. These two technology objectives (maximum, emissions-compliant cycle temperature and minimum air flow pressure drop) were integrated into a prototype design. The primarily analytical project sought to identify the most promising technologies to meet these objectives. Additional critical “jugular” data were obtained from multi-tube mixer tests to realize the potential of leveraging “micro flames” for minimizing overall hot surface area. This data was used, in conjunction with an understanding of advanced material and cooling design technologies, to analytically develop multiple design concepts. Phase I focused on in-depth engineering analysis and design, with minimal supporting laboratory testing to enable a selection of the top three combustion architectures for achieving these overall objectives. Phase II of the program developed the selected design through a combination of sub-scale testing and analytical efforts. Early tests included a cold-flow cascade to establish aerodynamic performance characteristics and a sub-scale fired test at GE Global Research in Niskayuna, NY, to establish cooling and heat transfer characteristics in conjunction with combustion performance. The data from these tests validated the analytical models to ultimately design a full-scale, test article to evaluate at prototypical pressure and temperature conditions at GE Gas Power’s Gas Turbine Technology Laboratory in Greenville, SC. GE Gas Power also developed, tested, and recommended a suitable seal design to be applied to the unique features of the combustor. To assess the technology challenges from prospective future production of the combustor from a ceramic matrix composite material, screening tests of Environmental Barrier Coatings were completed.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2023

A High-Magnetic-Field Polarized 3He Target for JLab's CLAS12 Spectrometer

We are developing a polarized 3He target for use in high luminosity electron scattering experiments within the high magnetic field environment of Jefferson Lab's CLAS12 spectrometer. By combining recent advancements in metastability exchange optical pumping (MEOP) of 3He with cryogenic, double-cell target methods as used for the MIT-Bates 88-02 experiment, a target with polarization and gas density comparable to traditional, low-field polarized 3He targets can be reached within high magnetic field environments. We have begun polarizing sealed 3He cells at fields up to 5 T at Jefferson Lab, and are preparing for our first tests exploring polarization performance versus magnetic field and gas pressure in a single cell before we move to the construction of a full, cryogenic, double-cell prototype target. A key focus of our research is the determination of polarization relaxation under the irradiation of an ionizing particle beam within high magnetic fields.

Maxwell, James↗
DOE OSTI2022

High Pressure and Two-Sided Mold Surface Solutions (CRADA Final Report)

This project provided surface solutions for highly loaded precision tooling relevant to the automotive industry. Previous development work in coatings for Big Area Additive Manufacturing (BAAM) has produced commercialized coatings for low temperature Acrylonitrile Butadiene Styrene (ABS) tools (TD Coat RT) as well as a soft coating for high temperature applications (TD Seal HT). The team developed these coatings and commercialized them during a prior Manufacturing Demonstration Facility (MDF) technical collaboration (NFE-15-05793). During the prior collaboration, commercialization testing was successfully performed by the Boeing and NAVAIR and resulted in an Awards for Composites Excellence (ACE), award at CAMX – The Composites and Advanced Materials Expo 2016. While this work was clearly successful, gaps in the technology were identified, that prevent widespread adoption of large-scale additive manufacturing in high pressure tooling applications prevalent in the automotive industry. In this project we focused on development of surface solutions for two-sided, compression molding tooling printed on a large-scale polymer AM system in an arbitrary build orientation. We have printed a single cavity extrusion compression molding mold using Polyphenylene sulfide/carbon fiber (PPS/CF) materials, 50% by weight CF samples. These processes are commonly used by Original Equipment Manufacturers (OEM) and Tier 1 suppliers for high volume automotive applications. Several OEMs have identified the need for such technology, indicating significant time and monetary savings could be possible if commercially available surface solutions for high pressure Additive Manufacturing (AM) tooling existed.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Suggestions on the Vapor Pressure Determination of Molten Salts

The knowledge of the thermophysical properties of coolant and fuel in molten salts nuclear reactors (MSRs), such as thermal stability and vapor pressure, are of remarkable interest, particularly for simulating safe reactor operations. Molten salt reactorsMSRs use molten salt mixtures as the primary coolant and/or fuel and are expected to operate up to 800 °C. With the revival of interest in deploying MSRs, complete thermophysical and thermochemical characterization of these materials is of interest to industry, regulators, and researchers. Vapor pressure data for molten salts are scarce in the literature, both for pure salts but especially for eutectic mixtures. This report describes the effusion method, which consist of measuring the rate of escape of vapor molecules through a small orifice for the determination of the vapor pressure of compounds and may be useful on compounds such as molten salts. Thermogravimetric analysis records the mass loss as a function of time and temperature. There are two equations that can be used to relate the mass loss rate with the vapor pressure: (1) the Knudsen equation and (2) the Langmuir equation. To apply these equations, the system needs to reach a pseudo (or near) equilibrium condition. Therefore, the experimental conditions must be such that allow the condensed and the vapor/gas phases to be in equilibrium. In order to accomplish equilibrium like conditions, the sample must be in an almost-sealed cell except for a small orifice, from where the vapor escapes. In the Knudsen method vacuum is applied to eliminate the effect that the presence of other gas molecules could have on the evaporation rate of the sample. However, Langmuir alleged that in certain conditions, such as at low temperatures and/or when the vapor pressure is low, the rate of evaporation of a substance is independent of the presence of vapor around it. For that reason, some researchers, when measuring the mass loss of a substance with a predictable low vapor pressure, do not apply vacuum when using the Langmuir equation. However, they use a standard substance to parameterize the experimental setup. The use of one equation or the other will depend on the characteristics of the sample and the availability of an appropriate standard. Some important aspects related to the nature of the samples and vapor pressure measurements are described for future consideration.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗