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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

High-Efficiency Low-Carbon Fuel Flexible Burner for Steel Industry

GTI Energy, with Bloom Engineering, Argonne National Laboratory and Oak Ridge National Laboratory, are developing the FlexGen-H burner. This high-efficiency burner can achieve 45•100% CO2e emissions reduction using green hydrogen with natural gas. It offers NOx, CO emissions ?50 ppm (3% O2), 15•51% fuel savings, ?50% PM2.5 reduction with turndown of ?5:1. The technology can work with renewable liquid fuels, ethanol or methanol. The technology aims to significantly reduce emissions, enhance resiliency, improve process efficiency. The paper will discuss preliminary results of development, with planned laboratory validation including safety, CFD, burner system design and market for the technology.

Sperry, McKay [ORNL] (ORCID:0009000658602049)↗
DOE OSTI2024

Development of 250 kW Ammonia and Hydrogen Industrial Burner Test Facility at the National Energy Technology Laboratory

In an effort to investigate the viability of ammonia and hydrogen as fuels in the industrial heating sector, the Department of Energy’s National Energy Technology Laboratory is developing a 250 kW burner test facility. The pursuit of a decarbonized industrial heating sector requires innovative approaches to convert existing assets to alternative fuels while maintaining adequate radiative heat transfer and limiting NOx. This new capability will leverage NETL’s experience and prior investments in ammonia and hydrogen combustion, to advance atmospheric pressure industrial combustion systems for industries such as cement kilns and glass factories. The intention in coming years is to collaborate with burner manufacturers and heavy industry partners to study, develop, and validate strategies for converting existing hardware from carbon-based fuels to next-generation clean ammonia and hydrogen technologies.

May, Kristyn Johnson↗
DOE OSTI2025

Combined TDLAS and chemiluminescence imaging in a flat flame burner operated with NH3/H2 blends

Ammonia is viewed as a viable hydrogen carrier due to favorable storage and transport characteristics. While it can be re-converted to hydrogen at point-of-use via thermal catalytic cracking, direct utilization in combustion systems can result in reduced costs and improved efficiency. A major barrier to this approach is the low flammability and potential for high nitrogen oxide emissions, driven by fuel-bound nitrogen and complex kinetic pathways. While a number of kinetic mechanisms currently exist for simulating ammonia combustion, a major need continues to be direct information about species profiles in easy-to-model systems capable of isolating chemical kinetics from multi-dimensional fluid dynamic effects. This paper reports on recent species measurements made in a flat flame burner using a combined tunable-diode-laser-absorption-spectroscopy (TDLAS) and chemiluminescence imaging approach. Three flame conditions were included representative of NH3/H2 blends, partially cracked NH3 (inc. N2), and 100% NH3 with enhanced air (30% oxygen). Two NIR distributed feedback (DFB) laser diodes were used to determine H2O concentration and temperature (via ratio thermometry) at various radial and axial positions, after which an inverse Abel transform was used to infer centerline values. Companion images were collected using a Princeton Instrument PI-MAX intensified camera equipped with a 105mm UV lens and multiple filter sets targeting OH*, NH*, and NH2* emission. Results were compared to companion Cantera burner-stabilized flame simulations using various kinetic mechanisms. A recent mechanism including excited species chemistry was also included, to investigate whether excited and ground state profiles exhibit significant differences.

ammonia combustion↗
DOE OSTI2024

Enclosed Sydney Swirl Burner Experimental Data Set - Release 1.0

This submission includes a comprehensive data set for the NETL Enclosed Sydney Swirl Burner, generated between 2012 and 2014. The data set includes global parametric data and advanced diagnostic data for (3) flames of interest to CFD model validation. The submission includes a companion summary document describing the data and associated references.

Diagnostics↗
DOE OSTI2025

Climate-focused Life Cycle Assessments of Biochar Production by an ARTi Pyrolysis Reactor and an Air Burners CharBoss® Air Curtain Incinerator

This report presents a limited, dynamic, consequential life cycle assessment (LCA) to compare the climate impacts of two biochar production methods using wood as a feedstock. The two methods are a pyrolysis reactor supplied by ARTi (Des Moines, IA, https://www.arti.com/) and a T26 CharBoss® air curtain incinerator supplied by Air Burners, Inc. (Palm City, FL, https://airburners.com/). The underlying LCA methodology is described in a chapter by Singh et al. (2024) and implemented in the form of a workbook freely available as online Supplementary Material for the chapter. For the convenience of the reader, a pre-print version of the relevant portions of Singh et al. (2024) is attached as Appendix A to this report. Specific assumptions and calculations to obtain the input parameters used in this LCA for each production method are described in the Methodology section below. This implementation of the LCA considers emissions associated with biomass loading, comminution and conversion, biochar decay in soil, and the production and use of bioenergy generated during the conversion process. The LCA is “limited” in that upstream emissions associated with biomass production, harvest, transportation, and land-use change, as well as embodied emissions in equipment and facilities are not considered. Similarly, downstream emissions from biochar transport and incorporation into soil (i.e., tillage), and the impact of biochar soil amendments on soil greenhouse gas (GHG) emissions (other than CO 2 from biochar decay in soil), soil organic carbon stocks, crop response, and surface albedo are not considered. As the intent is to compare different biochar production methods in a simple unbiased manner, the primary alternative biomass pathway for the LCA is immaculate combustion, which is the hypothetical instantaneous and complete conversion of carbon in the biomass to CO 2 at time zero without generation of any other greenhouse gases or aerosols (GHGAs) or any useful bioenergy. Use of this pathway provides relative values for the production methods and, when the embodied emissions are similar and the same feedstock is used, these relative values are reasonable approximations for those attained with a full LCA.

09 BIOMASS FUELS↗
DOE OSTI2025

Accident Progression and Source Term Demonstration Calculations for the Advanced Burner Test Reactor (ABTR)

As advanced reactor designers approach broad deployment of new reactor technologies and the associated applications, a critical milestone on this path includes licensing or authorization of these designs in the current regulatory environment. Commercial licensing and DOE authorization both consist of numerous aspects to not only certify the designed plant will operate as intended, but also related to confirmation of the safe operation of these facilities that comply with specific standards and requirements. To that end, domestic industry and regulators require toolsets and methods which can be used to confirm that advanced reactor designs not only align with expected performance during normal operation, but also a series of transient scenarios. These codes require a satisfactory validation basis, and in the absence of such a basis, code-to-code comparisons are often utilized as a surrogate to confirm model adequacy. To support this need for fast reactor technologies, a series of analyses using SAS4A/SASSYS- 1 and the Simplified Radionuclide Transport (SRT) code have been conducted for the Advanced Burner Test Reactor (ABTR). These analyses are expected to not only provide a baseline for transient and source term analyses of ABTR, but to also provide context for the key physics that determine evolution of specific transient scenarios in a sodium-cooled fast reactor (SFR). These codes are utilized for this work given their adoption in the SFR industry and by key SFR stakeholders.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Emissions Characterization for Ammonia Fuel Blends in an Enclosed Swirl-Stabilized Diffusion Burner

This study investigates ammonia flames using the enclosed Sydney swirl burner (ESSB), focusing on detailed global emissions measurements. Emissions were measured via Fourier-transform-infrared (FTIR) spectrometer, utilizing a heated, long-path absorption cell. Hot, wet measurements of pertinent species were collected, and concentrations were determined via lineshape fitting in conjunction with the HITRAN database. Results show that partially cracked ammonia compositions yield lower emissions compared to pure NH3/H2, and small amounts of NH3 addition to CH4-containing fuel blends exhibit high levels of NOx and CO, with measurable HCN and unburnt CH4. Equilibrium calculations suggest trade-offs between chemical timescale, heat loss, and mixing. Future work will explore emissions sampling procedures and expand analysis using chemical reactor network modelling.

ammonia combustion↗
DOE OSTI2025

Development of Hydrogen Burner for FT4000® Aeroderivative Engine - Final Report

This report details an effort to develop a retrofittable fuel/air injector for the FT4000® aeroderivative gas turbine that enables use of hydrogen as a carbon-free fuel for efficient power generation. The FT4000 engine’s low-NOx combustor was developed by Pratt & Whitney and RTX Technology Research Center with core technology from the Pratt & Whitney PW4000 turbofan aircraft engine. The current FT4000 production engine operates on either natural gas or No. 2 fuel oil with water injection to achieve high thermal efficiency and low emissions. This engine is fielded by Mitsubishi Power Aero and delivers 70 MW of power with a simple-cycle efficiency of over 41% when operating with wet compression. The work reported here advances the technology readiness level of the FT4000 combustor for operation with hydrogen, starting with an experimental assessment of the current production hardware with increasing hydrogen content mixed with natural gas and ending with improved nozzle concepts for fully robust operation with 100% hydrogen. High-pressure single-sector combustor rig tests have been completed, demonstrating the ability for the dual fuel nozzle to operate an FT4000 combustor on 100% hydrogen with low nitrogen oxide (NOx) emissions. Metal temperature measurements and video images of the flame structure from zero to 100% hydrogen highlight opportunities to improve the fuel nozzle robustness for high hydrogen conditions. The design of new fuel/air mixer concepts to improve durability and operability with high hydrogen levels was also completed. A total of eleven new concepts were developed and analyzed, ranging from modifications to the bill-of-materials nozzle to fully clean sheet designs. The concepts were evaluated with non-reacting and reacting flow evaluations to assess the performance of the new hardware designs. Non-reacting tests included Phase Doppler Particle Analysis (PDPA) for droplet size and velocity, mechanical patternation for liquid water flux, and planar laser induced fluorescence (PLIF) with acetone-seeding for gaseous fuel/air mixing characterization. Five scaled candidate fuel nozzle designs, in addition to a scaled bill-of-materials nozzle, were then successfully evaluated in an atmospheric pressure burner rig. The nozzles were evaluated for performance with natural gas, hydrogen/natural gas blends, and pure hydrogen. For 100% hydrogen, the nozzles were evaluated with and without water injection. Optical and infrared imaging of the flame and fuel nozzle was captured. NOx emissions were sampled from fixed emissions probes. The results show measurable differences between the various designs, and the data was used to down-select the two most promising designs to advance to future full pressure rig testing. Results from this study have cleared the current production FT4000 engines with dual fuel nozzles to operate at baseload power on blends of hydrogen mixed with natural gas and water. Two promising nozzle designs have been developed to enable fully robust operation with up to 100% hydrogen. These nozzles require validation at full baseload operating conditions before they can be introduced to the field.

03 NATURAL GAS↗
DOE OSTI2025

Combined TDLAS and chemiluminescence imaging in a flat flame burner operated with NH3/H2 blends

Ammonia is a promising hydrogen carrier due to its favorable storage and transport characteristics. However, its direct use in combustion systems is limited by low flammability and potential for high nitrogen oxide emissions. To better understand ammonia combustion, researchers conducted experiments using a flat flame burner and measured species profiles using tunable-diode-laser-absorption-spectroscopy and chemiluminescence imaging. They tested three flame conditions with different ammonia-hydrogen blends and oxygen levels. The results were compared to simulations using various kinetic mechanisms, including one that accounts for excited species chemistry. The goal is to provide direct information about species profiles in a simple system, isolating chemical kinetics from fluid dynamic effects, which can inform the development of more efficient and low-emission combustion systems using ammonia.

ammonia combustion↗
DOE OSTI2025

Glovebox Fires Phase 1: Simulations of Open Burner Experiments

Understanding the duration of a fire required to breach a glovebox via glove ports and/or windows within a facility is important in developing mitigation strategies for safety. To facilitate this understanding, both simulation and experiments are utilized. The approach is to first validate the Computation Fluid Dynamics (CFD) code, Fire Dynamics Simulator (FDS), with experimental data collected by New Mexico Tech (NMT) and then perform simulations of full-scale rooms containing gloveboxes to assess numerous scenarios which would otherwise be cost-prohibitive experimentally. This report provides comparison to first-phase experiments involving a fire without a glovebox. A subsequent report will provide comparison to experiments involving a glovebox. The results indicate good agreement with FDS tending to over predict the pre-mixed and diffusion-mode tests by 6% and 10%, respectively.

42 ENGINEERING↗
DOE OSTI2025

HIGH-FIDELITY SIMULATION OF SOOT FORMATION AND THERMAL RADIATION IN A LABORATORY-SCALE RICH-QUENCH-LEAN BURNER

High-fidelity simulations of a swirl-stabilized turbulent spray flame in a laboratory-scale aero-combustor have been performed to evaluate the predictability of state-of-the-art models in capturing soot formation. The simulations employ a complex chemical mechanism developed for Jet-A with PAH chemistry, coupled with the Hybrid Method of Moments (HMOM) soot model, and a Lagrangian dilute spray model for the fuel injection. Two simulations are performed to compare the results when thermal radiation is neglected or included in the solution with a mean spectral model. Modeling closures for the soot differential diffusion effects in mixture fraction space, as well as turbulence-radiation interaction are also evaluated using the data generated by the simulations. Given the degree of complexity of the simulation, the results showed good agreement with experimental measurements of the spatial distribution of the soot volume fraction ensemble average. A closer agreement with the experiment is observed when thermal radiation is included in the solution. Thermal radiation is observed to reduce the flame temperature and increase the flame intermittency, denoted by the increase in the temperature standard deviation in mixture fraction space. The reduction in temperature also leads to a reduction in PAH production and soot volume fraction. Turbulence is observed to have different effects on radiative emission depending on the mixture fraction. Turbulent scalar fluctuations significantly enhance radiative emission in fuel lean mixtures and can also play a role for fuel rich conditions. The statistical description of the turbulence-radiation interaction, previously proposed in the literature, was observed to correctly reproduce the high-fidelity results. Model coefficients were provided for swirl-stabilized flames. The soot differential diffusion model, previously proposed in the literature, based on the residual between the exact term and its model approximation, was also evaluated. The residual correction term further improved the agreement with exact differential diffusion term evaluated with the high-fidelity simulation data in mixture fraction space. The results suggest that the effective turbulent Lewis number can be equal to unity in simulations of turbulent non-premixed recirculating flames.

Soriano, Bruno [Sandia National Laboratories (SNL)↗
DOE OSTI2025

Flame Characterization of a Hydrogen Micromix Burner using Experimental and Numerical Methods - Extended Abstract

Micromix combustion presents a promising solution for integrating hydrogen into gas turbine combustors, offering rapid and compact air-fuel mixing that effectively shortens the combustion zone and significantly reduces nitrogen oxides (NOX) emissions. A major challenge in hydrogen combustion systems is flashback, which is mitigated through short mixing lengths and high flow velocities. This study investigates three fuel injector designs – zero swirl, low swirl, and high swirl – for a 6-mm inner diameter nozzle, where hydrogen is injected through six 0.3 mm diameter holes in a jet-in-crossflow configuration relative to the airstream. Numerical simulations indicate stable flame formation, moderate peak flame temperatures, and subsequent low NOx potential for all designs. These injectors have been fabricated using additive manufacturing, and upcoming experiments will explore flame structure and NOx behavior across varying fuel injection angles, equivalence ratios and pre-mixer velocities. These efforts aim to advance the development of low-emission hydrogen micromix combustion.

hydrogen↗
DOE OSTI2024

Impact of a Bluff Body on a Pressurized Oxy-fuel Flame

Designing an effective burner is vital for the development of pressurized oxy-fuel combustion technologies. In the present work, turbulent jet diffusion burners are adopted for a pressurized oxy-combustor, with a bluff-body employed to create a recirculation zone, thereby stabilizing the flame in such a combustor. The objective of this numerical study is to perform a systematic analysis of the characteristics of such a pressurized non-premixed flame. Specifically, a 15-bar pressurized oxy-fuel combustor of power 100 kWth is modeled by means of the Ansys FLUENT commercial platform, using the Reynolds-averaged Navier-Stokes (RANS) approach. The present work focuses on identifying the aerothermodynamic features of the pressurized oxy-fuel burner with a disk-shape bluff-body. It is shown that the fuel-to-oxidizer stream momentum ratio has a great impact on the temperature profile of the down-fired, co-axial, pressurized oxy-coal, diffusion flame. A parametric study of the blockage ratio of the burner identifies an optimal range for this pressurized burner.

Li, Lei↗
DOE OSTI2024

High-Speed OH-PLIF Diagnostics of Flame Flashback in Low Swirl Hydrogen-Enriched Flames

This paper reports flashback events observed in hydrogen-enriched flames stabilized in a low swirl burner (LSB) at atmospheric pressure and temperature conditions. The fundamentals of hydrogen-rich stable flames and spatiotemporal investigation of flashback phenomena were observed experimentally using a high-repetition-rate nanosecond (ns)-duration hydroxyl radical planar laser-induced fluorescence (OH-PLIF) diagnostic. Testing was conducted in an optically accessible pre-mixing section of a LSB with inlet pre-mixing velocities ranging from 5 to 10 m/s for methane and hydrogen (50 – 90% by mole) blends. Swirlers with two different turning angles, 26o and 33o, and three different perforated plate hole diameters, 1.08, 1.12 and 1.16 mm, with measured swirl numbers varying from 0.43 to 0.49 were used in this study at atmospheric temperature and pressure inlet conditions. The flashback propensity showed a dependence on the proximity of the lifted flame to the burner exit (termed as lift-off length, L) which was dependent on the pre-mixer velocity (V), hydrogen content (XH2) and equivalence ratio (ϕ) at constant temperature and pressure conditions. High-speed OH-PLIF images revealed lifted flames were first observed at low ϕ/ XH2 condition which then changed to a M-shaped flame attached to burner rim with the increase in ϕ/ XH2. Further increases in ϕ/XH2, depending upon other inlet parameters, triggered flame flashback into the pre-mixing section. Flashback occurred when burning began in the outer shear layer and the leading flame brush propagated into the nozzle. Such spatiotemporally resolved high-speed OH-PLIF imaging provides insights on different stages of flashback in a LSB – flashback initiation, transition of flame propagation from burner exit to the swirler and flashback to flame holding transition. Flame ϕ at flashback showed an expected linearly increasing trend with increasing V and decreasing XH2 and the conclusions drawn aligned well with detailed investigations. For identical inlet conditions, flashback propensity decreased with increasing perforated-plate hole diameter and increasing swirler vane angle.

Parajuli, Pradeep↗
DOE OSTI2025

Towards stabilization of pressurized oxy-coal diffusion flames

Designing an effective burner is vital for the development of pressurized oxy-fuel combustion technologies. Turbulent jet diffusion burners are adopted for the pressurized oxy-combustor in this research and a bluff-body is employed to create a recirculation zone to stabilize the flame in pressurized oxy-combustor. The objective of this numerical work is to perform a systematic analysis of the characteristics of this pressurized non-premixed flame. Specifically, a 15-bar POFC combustor of power 100 kWth is modeled employing the Ansys FLUENT commercial platform, using Reynolds-averaged Navier-Stokes (RANS) modeling. The present computational work focuses on identifying the aerothermodynamic features of the isothermal and reacting flow with a disk-shape bluff-body. Results show that fuel-oxidizer stream momentum ratio has great impacts on the temperature profile of the down-fired, co-axial, pressurized oxy-coal, diffusion flame. Parametric study of the width of the burner tip identifies an optimal range for this pressurized burner.

Li, Lei↗