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DOE OSTI2024

Comparative Analysis of Heat Exchangers for High Temperature High Pressure Helium Component Testing

Helium gas loops have been designed and built to gain a better understanding of the gas thermohydraulic phenomena that take place in a helium system. Some of these loops are used for validation and testing of components for high temperature gas-cooled reactors (HTGRs). However, most of them operate at lower pressure and temperature than an HTGR. While these loops can provide valuable information about gas-cooled reactor components, the operating envelope of the experiment is constrained by the maximum operating conditions of the helium loop. In response to the lack of an experimental facility that can provide the infrastructure needed to validate and test components at nominal pressures and temperatures of HTGRS, the HElium Component Testing Out-of-pile Research (HECTOR) facility was designed at Idaho National Laboratory with the assistance of University of Idaho and Walsh Engineering. With the capability to test at temperatures up to 800°C and pressures of 8MPa, HECTOR serves as a critical tool for the advancement of HTGR technology. The facility's primary role is to provide a controlled, high-fidelity environment for the assessment of component resilience and efficiency under nominal HTGR conditions. In the quest to enhance the efficiency and performance of HECTOR, a comparative analysis of three distinct types of heat exchangers—shell and tube, offset strip fin, and printed-circuit—was conducted, focusing primarily on two critical metrics: the required surface area and pressure drop characteristics. The shell and tube heat exchanger, renowned for its robust design and widespread industrial application, was evaluated against the offset strip fin and the cuttingedge printed-circuit heat exchangers, both of which are lauded for their compactness and thermal effectiveness. This comparative study aims to provide detailed insights into the thermal management capabilities of each heat exchanger type under the conditions inherent to HECTOR, thereby facilitating an informed selection for systems demanding high operational integrity and efficiency.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Optimal operation of multi-plant steam district heating systems for enhanced efficiency and sustainability

Despite their crucial role in supplying heat and power to universities, industries, and healthcare facilities, many steam-based district heating systems rely on outdated control methods. Among these, multi-central plant districts are particularly challenging due to the complexities of coordinating multiple plants, optimizing load distributions, and managing system downtime. In response, new operational strategies are developed to enhance the efficiency and sustainability of steam districts while utilizing existing resources. These strategies include reducing plant operational pressure without compromising the reliable supply to buildings and optimizing load allocation across multiple plants. The load allocation considers boiler part-load efficiency, runtime, network losses, and building pressure set points, and is compared with traditional multi-boiler controls. To support this exploration, new dynamic Modelica models are developed. In addition, methods to reduce modeling complexities are incorporated, enhancing their suitability for practical applications. A holistic district-wide analysis using a real university case study demonstrates a 4.7% fuel savings by lowering boiler operational pressure from 900 kPa to 600 kPa, along with a 13.3% reduction in condensation losses across the distribution network. Furthermore, the load allocation approach results in a 13.1% reduction in fuel consumption during peak winter periods and 15.3% during shoulder periods, with corresponding decreases in carbon emissions and fuel costs. This approach can also save maintenance costs by reducing the boiler runtime by 49.6%. In conclusion, this research underscores the benefits of retrofitting aging steam district heating systems, offering immediate operational improvements by enhancing efficiency, meeting regulatory compliance, and extending infrastructure lifespans while delaying costly overhauls.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

Promoted Ru/PrOx Catalysts for Mild Ammonia Synthesis

Ammonia synthesis is one of the most important chemical reactions. Due to thermodynamic restrictions and the reaction requirements of the current commercial iron catalysts, it is also one of the worst reactions for carbon dioxide emissions and energy usage. Ruthenium-based catalysts can substantially improve the environmental impact as they operate at lower pressures and temperatures. In this work, we provide a screening of more than 40 metals as possible promoter options based on a Ru/Pr2O3 catalyst. Cesium was the best alkali promoter and was held constant for the series of double-promoted catalysts. Ten formulations outperformed the Ru-Cs/PrOx benchmark, with barium being the best second promoter studied and the most cost-effective option. Designs of experiments were utilized to optimize both the pretreatment conditions and the promoter weight loadings of the doubly promoted catalyst. As a result, optimization led to a more than five-fold increase in activity compared to the unpromoted catalyst, therefore creating the possibility for low-ruthenium ammonia synthesis catalysts to be used at scale. Further, we have explored the roles of promoters using kinetic analysis, X-ray Photoelectron Spectroscopy (XPS), and in situ infrared spectroscopy. Here, we have shown that the role of barium is to act as a hydrogen scavenger and donor, which may permit new active sites for the catalyst, and have demonstrated that the associative reaction mechanism is likely used for the unpromoted Ru/PrOx catalyst with hydrogenation of the triple bond of the dinitrogen occurring before any dinitrogen bond breakage.

Chemistry↗

DOE OSTI2024

Computing the solubility of argon and xenon in molten sodium chloride and potassium chloride salts

Molten salt reactors (MSRs) offer significant advancements in nuclear reactor safety and efficiency by operating at higher temperatures and lower pressures compared to traditional reactors. A critical aspect of MSR operation involves understanding the solubility of fission byproducts, particularly noble gases, in the molten salts used. This study employs molecular dynamics (MD) simulations to compute Henry’s law constants and enthalpies of solvation for argon and xenon in molten sodium chloride (NaCl) and potassium chloride (KCl). We developed a new pairwise potential for the noble gas and salt interactions based on first principles calculations. We then used this potential to calculate Henry’s law constants of the two gases in the molten salts, which were modeled using both a rigid ion model (RIM) and a polarizable ion model (PIM). The solubility calculations, performed using the Widom insertion method, show qualitative agreement with limited experimental data, highlighting the temperature dependence and greater solubility of both gases in KCl compared to NaCl. Additionally, free volume analysis elucidated the role of available space within the molten salts in governing solubility trends. Our findings suggest that PIM trajectories provide more reliable predictions for noble gas solubility than RIM due to their accurate density representation. Furthermore, these results enhance understanding of gas solubility in MSR environments, and the methods can be readily extended to other systems.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2025

Review of the potential and challenges of MOF-based adsorption heat pumps for sustainable cooling and heating in the buildings

Heat pumps are regarded as the most suitable means to meet the future demand of heating and cooling in the building, as they require small input of electrical energy and output high thermal energy. Vapor compression heat pump (VCHP) and transcritical-CO 2 heat pump are the two major heat pump technologies currently dominating the market. However, VCHP system suffers from its fugitive emission of hydrofluorocarbon (HFC) refrigerants, and transcritical-CO 2 system requires high operating pressure (typically 9–13 MPa). For low-to-medium temperature heating and cooling applications thermally driven adsorption heat pump (AHP) provides a better alternative to VCHP and transcritical-CO 2 system as AHP uses natural refrigerants and operates at a much lower pressure. But currently available AHP technology has the limitation of low coefficient of performance (COP). Advances in synthesizing metal-organic frameworks (MOF) with high gas adsorption capacity have created an opportunity to address the problem of low COP of current AHP technology. Here, this article reviews the progress made in the past decade in utilizing MOF and conventional adsorbents with different working fluids in AHP technology and compares their performance. The article also summarizes the key challenges for the MOF-based AHP technology and provides the authors’ perspective to address these challenges.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2024

Development of Self-Assembly Supports Enabling Transformational Membrane Performance for Cost-Effective Carbon Capture

This final technical report describes work conducted by Membrane Technology and Research, Inc. (MTR) for the U.S. Department of Energy (DOE), National Energy Technology Lab (NETL) on the development of membranes with transformational performance for carbon capture under award number DE-FE0031596. The work was performed from June 1, 2018 through May 31, 2024. For more than a decade, MTR has worked in partnership with DOE to develop an innovative membrane-based CO 2 capture process. This effort has included the first test of membrane modules with coal-fired flue gas at the Arizona Public Services (APS) Cholla plant in 2010; the accumulation of >11,000 hours of flue gas operation for Polaris modules on a bench-scale 1 tonne/day (TPD) system at the National Carbon Capture Center (NCCC); scale-up of first-generation (Gen-1) Polaris to a 20 TPD small pilot system, and successful operation of this system on a flue gas slipstream at NCCC and in integrated boiler testing at Babcock & Wilcox (B&W). Through continued development efforts, a second-generation (Gen-2) version of the Polaris membrane has been scaled-up to pilot production. This membrane offers 70% higher CO 2 permeance with similar selectivity to the base case Polaris. MTR also developed planar modules designed specifically for the low-pressure, high-volumetric flow rate process conditions of flue gas operation. These new modules have significantly lower pressure-drop values compared to the type originally used (spiral-wound modules), which results in significant energy savings. The goal of the work described in this report was to improve on the Polaris Gen-2 membrane with the ultimate aim to reduce the cost of carbon capture. The majority of the effort was to develop improved support membranes for the multi-layer composite structure of MTR’s Polaris membrane. Earlier work at MTR had identified the support structure as limiting membrane permeances, not because the support itself represents a permeation resistance, but because the distribution of pores at the surface of the support imposes a geometric restriction to diffusion in the layers above it. Support membranes were prepared from a range of polymers, including commercially available block copolymers and a custom synthesized block copolymer alternative. The best support membranes developed in this project reduced the geometric restriction by a factor of two to three. These supports then were used to produce Polaris composite membranes with improved permeances. The second topic was to create a high-selectivity version of the Polaris membrane. The high-selectivity version uses a novel selective polymeric material and high selectivities were confirmed in experiments at MTR. The material is not easily made into very thin films. Consequently, the permeances are significantly lower than the Polaris Gen-2 membrane. The utility of this membrane is therefore limited to the carbon dioxide purification step that produces liquid CO 2 . A Technical and Economic Analysis (TEA) was performed for a carbon capture system that uses both advanced membrane types. The TEA shows the novel advanced membranes reduce the cost of capture by 10%, from $63.32/tonne CO 2 to $56.90/tonne CO 2 (2022 USD). Most of the development work was carried out with laboratory-scale casting and coating equipment. A number, but not all, of the improvements identified have been implemented on commercial-scale manufacturing equipment. The focus of future work at MTR is to incorporate the advancements made into the Polaris membrane manufacturing process.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2024

Large-Eddy Simulation Study of Flow and Combustion Dynamics in a Full-Scale Hydrogen–Air Rotating Detonation Combustor-Stator Integrated System

In the present work, a first-of-its-kind three-dimensional (3D) large-eddy simulation (LES) study is conducted to numerically investigate the combustion dynamics as well as aero-thermal phenomena in a full-scale nonpremixed hydrogen–air rotating detonation engine (RDE) (with a diverging-shaped lower-end wall), when integrated with nozzle guide vanes (NGV) acting as the turbine stator. The wall-modeled LES framework incorporates hydrogen–air detailed chemical kinetics and adaptive mesh refinement (AMR). A comparative analysis is carried out for two operating conditions with different fuel/air mass flow rates but global equivalence ratio of unity, and considering RDE configurations without and with stator. The LES model is validated against available experimental data for the low mass flux condition with respect to detonation wave speed/height, wave dynamics, and axial static pressure distribution. Numerical results indicate significant deflagrative combustion occurring in the fill region near the inner wall due to formation of recirculation zones in the injection near-field driven by the backward facing step. The leading detonation wave is found to be trailed by an azimuthal reflected-shock combustion (ARSC) wave, consistent with experimental observations, which consumes unburned vitiated reactants that leak through the main detonation wave. The main detonation wave characteristics, such as detonation wave speed/height and combustion efficiency, do not change appreciably with the presence of NGV. A novel combustion diagnostic technique based on chemical explosive mode analysis (CEMA) is employed to quantify the fraction of heat release occurring in the detonative mode versus deflagrative mode for the simulated conditions. The exit flow is found to be nearly fully subsonic and supersonic for the low and high mass flux conditions, respectively. Further analysis of the exit flow profiles shows that the presence of NGV renders the flow more axial and significantly impacts the exit Mach number and total pressure, while the total temperature shows negligible change. In addition, the low mass flux operating point, despite exhibiting more deflagrative losses within the combustor, yields overall lower pressure drop from plenum to exhaust, which is mainly attributed to lower pressure drop across the injectors. Lastly, the rotating detonation engine-nozzle guide vanes (RDE-NGV) configuration exhibits higher total pressure loss compared to rotating detonation engine (RDE) without stator across both the mass flux conditions. In conclusion, this study extends the state-of-the-art in numerical modeling of pressure gain combustion (PGC) systems by demonstrating high-fidelity 3D reacting LES of full-scale RDE-NGV systems relevant to RDE-turbine integration for stationary power generation.

Combustion↗

DOE OSTI2025

Operation of helium sub-atmospheric multistage cryogenic centrifugal compressor trains: Part 1 – Steady state modeling and speed ratio selection

Helium cryogenic systems which can provide cooling below the normal boiling point of helium (approximately 4.2 K) are often required by superconducting radio-frequency niobium resonators utilized in modern high-energy particle accelerators. Achieving temperatures below 4.2 K generally involves operating a cryogenic vessel with liquid helium under sub-atmospheric conditions, thereby lowering the saturation pressure and corresponding saturation temperature. Over the last several decades, multi-stage cryogenic centrifugal compressor trains (CC’s) have been operated efficiently and reliably within large-scale cryogenic systems to continuously evacuate helium vapor generated by a device within the vessel, maintaining sub-atmospheric conditions in the vessel while pressurizing the return vapor to above atmospheric conditions. Traditionally, these CC systems have been operated using empirically derived control philosophies and insight gathered from previous operational experience. Recent efforts at the Facility for Rare Isotope Beams (FRIB) have been aimed at the development of a theoretical basis to characterize the operation of multi-stage cryogenic centrifugal compressor train and utilizing predictive model results to generate control parameters. The objective of this research was identifying operational points which adequately balance cryogenic system efficiency, stability, and overall ease of operation. Furthermore, this manuscript provides an overview of the predictive model development, characterization of the FRIB cryogenic centrifugal compressors and implementation of the predicted performance results during steady-state system operation.

Compressor train control↗

DOE OSTI2026

Cold compressor performance and energy consumption improvements at Jefferson Lab’s Central Helium Liquefiers

Abstract Jefferson Lab operates two central helium liquefiers (CHLs) which both utilize full cold compression from the saturation pressure at operating temperature (approximately 2.1 K) to just over atmospheric pressure. The original plant, CHL1, was recently outfitted with a replacement subatmospheric cold box (SC1R) containing state-of-the-art cold compressor technology, while the newer plant, CHL2, uses an older cold compressor system. In both cases, the heat of compression is absorbed at low temperature at the expense of electrical power consumed by the warm compressors. Due to the superior efficiency and turndown capabilities of SC1R, a new operating mode has been identified for CHL1 in which the required number of operating warm compressors is reduced by one. A cost-based method for optimizing cold compressor stability and efficiency has been developed and applied to CHL2, improving its turndown and lowering the warm compressor discharge pressure. As a result of these efforts, power consumption of the combined CHLs during normal operations has been reduced by nearly 10%, or a total of 650 kW. The observed performance of CHL1 with SC1R, as well as the cold compressor optimization method, leading to this improved energy consumption rate will be discussed in detail.

Mastracci, B [Thomas Jefferson National Accelerato↗

DOE OSTI2024

Experimental Combustion and Flame Characterization of a Chemical Looping-Based Oxidative Dehydrogenation Byproduct Fuel Mixture Containing High CO2 Dilution

Abstract This study investigates the combustion performance of a CO2-rich fuel mixture containing ethane and methane as active species using a constant volume combustion chamber. This fuel is obtained as a byproduct of a chemical looping-based oxidative dehydrogenation (Cl-ODH) process ethylene production. The byproduct gas mixture has 40.79% CO2, 39.49% ethane, and 4.88% methane by weight with other minor compounds. Using this fuel for energy extraction would improve the process efficiency of the ethane to ethylene conversion. After initial combustion modeling, the gas fuel mixture was reduced to just the major species: CO2, ethane, and methane. The mixture was then tested for flammability limits and combustion performance under spark-ignition conditions. Effects of ambient conditions like temperatures between 300 and 400 K with initial pressures from 1 to 10 bar were tested. The effects of stoichiometry were tested to understand flame velocities and heat release. The fuel mixture showed an overall reduced flame velocity compared to gasoline. Instability in combustion was believed to be caused by the dissociation of ethane under elevated conditions. At higher pressures, the flame produces lower cumulative heat release. Simulations were also performed using a model tuned to replicate the operations of the combustion chamber used in the experiments. Heat release and unburnt fuel mass data were calculated to identify the discrepancies in the combustion completeness at elevated pressures. The effects of CO2 quenching the flame coupled with the increased dissociation of the fuel species can lead to up to more than 75% of the fuel mixture being unburnt. Data from this study were used to modify a small-scale spark-ignition engine to use this fuel and produce usable energy.

Energy & Fuels↗

DOE OSTI2025

Mesofluidic Inline Separation for Produced Water Treatment

Mesofluidic inline separation developed by PNNL represents an opportunity to remove a key barrier in the treatment of produced water, namely suspended solids that clog downstream operations. The US alone produces over 800 billion gallons of produced water each year, most of which is reinjected underground (but not into the aquifers) as waste. The impact from treating and reusing even a fraction of this wastewater is immense as aquifers in the Midwest and elsewhere dry. The work described herein is essential to leveraging the opportunity to improve produced water quality (to allow for beneficial use) by combining mesofluidic inline separators with reverse osmosis systems. Providing water for agricultural and industrial uses in the American Southwest and Midwest by allowing the reuse of petroleum produced water may be critical to the long-term economics of the region. This is especially true as drought conditions are rapidly lowering aquifer levels in these regions. The incumbent technology for desalination is reverse osmosis (RO) due to its ability to treat a wide range of feedwaters and technological maturity. However, suspended solids cause RO (and other dissolved solids removal technologies) to become clogged and loose performance. A common strategy is to use prefilters upstream of RO systems, but these membrane-based filters easily clog and require regular maintenance. Unlike membrane filters, mesofluidic inline separators provide removal of suspended solids with much lower pressure drops than conventional systems filtration systems, permitting substantially higher flowrates. Although the amount of produced water from petroleum operations is vast, only a small fraction of it is reused or turned into potable water, for example, because of the lack of technologies to remove both dissolved and suspended solids at a significant throughput. This project shows that mesofluidic inline separators coupled with a commercial dissolved solids removal technology (RO) are positioned to do exactly that. Mesofluidic inline separators fit within commercial piping and are tunable for particle sizes of interest as described below. Indeed, mesofluidic inline separators have remarkably smaller footprints than competing filtration technologies and are easily transportable from jobsite to jobsite. This technology has no moving parts so that solids removal can be accomplished at much lower operating cost.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2026

Demonstration of an All-Refractory Corrosion-Resistant Molten Salt Pumping and Storage Infrastructure Up to 950 degrees C

Concentrating solar power (CSP) with thermal energy storage (TES) has an estimated cost similar to solar photovoltaics (PV) with lithium-ion batteries (LIB), but CSP + TES has the potential for significantly reduced cost by operating above 700 degrees C. However, this requires a TES medium and containment infrastructure which are chemically compatible and do not degrade above 700 degrees C. MgCl2-KCl-NaCl (MKN) salt is a promising medium, but when MKN salt has small amounts of water and oxygen dissolved in it, it excessively corrodes conventional commercial alloys. Here, we consider refractory materials including graphite, carbon-carbon composite (C/C), and molybdenum because they maintain high mechanical strength at elevated temperatures and are expected to resist corrosion by MKN salt. While selection of refractory materials is often constrained by the need to remain chemically stable in air, this work uses an enclosure filled with inert gas to allow the use of materials like graphite and molybdenum. Notably, graphite components can seal against liquids unlike many brittle refractory materials. We demonstrate a centrifugal pump and mechanical seals made of refractory materials in a laboratory-scale circulation loop, which successfully operated continuously for more than 49 h at temperatures ranging from 750 degrees C to 950 degrees C with no mechanical failures or chemical degradation of the refractory materials. To the best of our knowledge, this is the highest temperature molten salt circulation loop that has been successfully developed, and this refractory infrastructure allows for operation at even much higher temperatures (<1600 degrees C) if a storage medium with a lower vapor pressure is used. The principles of this architecture are relevant to other applications with high temperature flowing metals and salts including Generation IV nuclear fission reactors for power production and molten salt electrolysis reactors for metallurgical processing.

14 SOLAR ENERGY↗

DOE OSTI2024

Advancing Li-plating detection: Motivating a multi-signal correlation approach

Facilitating fast charging in lithium-ion batteries (LiBs) is often linked to Li-plating, which harms performance, longevity, and safety. Early detection of Li-plating is essential for rapid technological development and for preventing performance deterioration and ensuring safety during operation. Fast and real-time detection, using commonly collected measurements like voltage (V), current (I), temperature (T), and pressure (P), is highly desirable. Existing standalone methods relying on electrochemical and mechanical signatures, using half, smaller, or specially designed cells often operated at lower temperatures, fail to account for real-world fast-charging conditions. These signatures may also have inherent unreliability in aged LiBs, a phenomenon currently not-well understood. All these uncertainties have complicated practical implementation of a robust Li-plating detection technique. This study, through multiple case studies involving real-world fast-charging conditions using automotive-grade 11.6 Ah LiBs, shows that many single signal-based diagnostic techniques may be inadequate to detect Li-plating. Among various signatures, end-of-charge rest pressure, differential pressure-sensing, and end-of-charge rest voltage were identified as particularly useful in detecting Li-plating. Furthermore, A multi-signal-based detection technique is shown to be more robust in detecting Li-plating. Using both fresh and aged cells, the results and analysis highlight how detection capabilities are influenced by various factors, including battery design, size, charging speed, operating temperature, and degradation level. Adopting such a multi-signal Li-plating detection approach may be instrumental in the rapid development of battery technology in laboratories, as well as ensuring the enhanced safety of next-generation LiBs in real-world fast-charging applications.

25 ENERGY STORAGE↗

DOE OSTI2024

Investigating instabilities in magnetized low-pressure capacitively coupled RF plasma using particle-in-cell (PIC) simulations

The effect of a uniform magnetic field on particle transport in low-pressure radio frequency (RF) capacitively coupled plasma (CCP) has been studied using a particle-in-cell model. Three distinct regimes of plasma behavior can be identified as a function of the magnetic field. In the first regime at low magnetic fields, asymmetric plasma profiles are observed within the CCP chamber due to the effect of $\overrightarrow{E}$ × $\overrightarrow{B}$ drift. As the magnetic field increases, instabilities develop and form self-organized spoke-shaped structures that are distinctly seen within the bulk plasma closer to the sheath. In this second regime, the spoke-shaped coherent structures rotate inside the plasma chamber in the -$\overrightarrow{E}$ × $\overrightarrow{B}$ direction, where $\overrightarrow{E}$ × $\overrightarrow{B}$ are the DC electric and magnetic field vectors, respectively, and the DC electric field exists in the sheath and pre-sheath regions. The spoke rotation frequency is in the megahertz range. As the magnetic field strength increases further, the rotating coherent spokes continue to exist near the sheath. The coherent structures are, however, accompanied by new small-scale incoherent structures originating and moving within the bulk plasma region away from the sheath. This is the third regime of plasma behavior. The threshold values of the magnetic field between these regimes were found not to vary with changing plasma reactor geometry (e.g., area ratio between ground and powered electrodes) or the use of an external capacitor between the RF-powered electrode and the RF source. The threshold values of the magnetic field between these regimes shift toward higher values with increasing gas pressure. Analysis of the results indicates that the rotating structures are due to the lower hybrid instability driven by density gradients and electron-neutral collisions. This paper provides guidance on the upper limit of the magnetic field for instability-free operation in low-pressure CCP-based semiconductor deposition and etch systems that use the external magnetic field for plasma uniformity control.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2025

Direct Air Capture Using Aqueous Amino Acid Solvents in a Crossflow Absorber

Carbon dioxide (CO 2 ) is the most abundant of all greenhouse gases (GHGs). CO 2 levels in the atmosphere are 50% higher than in the preindustrial era, trapping heat. CO 2 removal from the atmosphere by direct air capture (DAC) is needed to achieve the internationally agreed global temperature goals. The most common CO 2 capture technology is absorption by aminebased solvents in packed columns. Amino acid solutions have recently gained attention due to their advantages over traditional amine solvents. To be implemented effectively, DAC industrial processes need to handle large airflow rates in separation absorbers. The large air and solvent flow rates preclude the use of countercurrent columns due to high-pressure drops and the occurrence of flooding. Crossflow air−liquid absorbers are used to handle large air and liquid volumes due to their lower-pressure drop. The objective of this work is to study the influence of crossflow absorber geometric parameters and operating conditions on product formation and process efficiency. An already derived theoretical model for countercurrent absorbers has been modified to simulate the operation of a crossflow DAC absorber. The predictive model was implemented into a computer code that was used to study the efficiency of the processes as geometric equipment dimensions and operating parameters vary. Practical suggestions are made to design more efficient DAC processes.

Absorption↗

DOE OSTI2026

Total Cost of Ownership Reduction Using Passive Pre-Chamber Ignition in Natural Gas Engines

Spark plug durability is a factor affecting the total cost of ownership (TCO) of spark-ignited natural gas engines, with some heavy-duty platforms requiring plug replacement after only 750 hours of operation. The high ignition energy demand under lean or diluted conditions accelerates electrode wear, shortening plug life and increasing maintenance frequency. This work evaluates passive pre-chamber (PC) ignition operating at lowered spark energies as a strategy to reduce spark energy requirements and extend plug durability, thereby lowering TCO. Experiments were conducted on a medium-duty Cummins 6.7L ISB engine at 1600 RPM and 50% load under varying exhaust gas recirculation (EGR) dilution levels (0–40%). Two passive pre-chambers with 1.1 mm and 1.6 mm nozzle diameters were compared with conventional spark ignition (SI). SI was operated with a fixed coil dwell of 4 ms (~90 mJ), while the PC configuration was tested across 2–4 ms dwell times (~30–90 mJ). Cylinder pressure analysis revealed that PC ignition sustained stable combustion at significantly lower spark energies than SI, with improved combustion stability at ~30 mJ compared with SI at ~90 mJ. The PC system also extended the dilution tolerance beyond that achievable with SI, while delivering up to ~2% higher indicated thermal efficiency and reducing the COV by nearly 90% at 30% EGR. A TCO analysis was conducted to assess the economic benefit of adopting a passive PC system operating at reduced spark energies compared to SI. It was found that adopting a passive PC system could reduce TCO by approximately $11,000 per engine over a five-year operational period, primarily due to fuel savings, extended spark plug life, and reduced maintenance frequency. These projections were weighed against the additional hardware cost of the pre-chamber, yielding a rapid estimated return on investment of ~300 operating hours. Therefore, this work motivates continued research and development of passive PC technology and its commercial adoption in natural gas engines used in transportation applications.

Dhotre, Akash [University of Minnesota]↗

DOE OSTI2026

Tar Formation and Mitigation in Pressurized Biomass and Cofired Gasification

Biomass gasification with CO2 capture has the potential to provide carbon-negative heat, power, and feedstock for sustainable hydrocarbon fuels. In a pressurized gasifier, precombustion solvent systems can capture CO2 with less energy than needed for amine-based postcombustion CO2 capture, and pressurized syngas is generally more suitable for fuel synthesis. Although precombustion capture has been used for many decades in large-scale fossil-based plants, it has not been well-demonstrated in smaller-scale biomass gasification. Precombustion solvents and product streams could be particularly impacted by tar and other organic compounds that tend to form in high concentrations during low-temperature biomass gasification. A pressurized pilot-scale gasifier was used to examine tar formation and fate when using CO2 capture with various blends of biomass and coal. The syngas was fully conditioned to remove particulate matter; capture sulfur; adjust syngas chemistry using water-gas shift; quench out moisture and condensable organics; and capture CO2. Tar concentrations were measured in the raw syngas, the product gas, and in the liquid streams over the course of several weeks. The gasifier was operated both as a high-pressure oxygen-blown system to mimic large-scale centralized gasification and at lower pressures under air-blown conditions to mimic a more likely small-scale system. A second high-temperature stage with oxidant injection was used to crack tars. The overall results showed how gasifier and CO2 capture performance change as fuel is blended between coal to biomass and what the fate of tar is through a precombustion CO2 capture system.

Strege, Josh [University of North Dakota EERC] (OR↗

DOE OSTI2024

Evaluation of Common Thermoplastic Polymers in High-Pressure Cycling Hydrogen Under Ambient and Cold Environments as Applicable to the Hydrogen Infrastructure

Thermoplastic polymers are required to perform unfailingly under stringent conditions of changing pressures (35 MPa to 70 MPa) and temperatures (-40°C to +85°C) in storage and fueling operations. Although diffusivity in glassy polymers appear to be an order of magnitude lower than elastomers, polymer microstructural attributes such as degree of crystallinity and presence of polar and non-polar groups on the main chain with and without branching can play a substantial role in influencing their behaviors in hydrogen environments. In the work described here, the effect of high-pressure hydrogen cycling on PEEK, PTFE, PA11, HDPE, POM (and different commercial grades of these polymers) under ambient and cold (-40°C) conditions is addressed. Ex-situ characterization for polymer changes included density measurements for impact of hydrogen retention, hardness changes using nanoindentation, storage modulus and glass transition changes using dynamic mechanical and thermal analysis (DMTA), degree of crystallization with Differential Scanning Calorimetry (DSC) and tensile testing following ASTM D412. In other evaluations, solid-state nuclear magnetic resonance (NMR), attenuated total reflectance Fourier transform infra-red spectroscopy (ATRFTIR), X-ray diffraction (XRD), and X-ray CT results are presented. The overall impact of these evaluations is to establish a technical basis for the behaviors of common thermoplastics in cycling hydrogen environments under ambient and cold temperatures while establishing the relationship between polymer structure-based properties and hydrogen transport effects.

Menon, Nalini C.↗