Effects of Pressure and a Microporous Coating on HFC-245fa Pool Boiling Heat Transfer
Abstract not provided
30 DIRECT ENERGY CONVERSION↗
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Effects of Pressure and a Microporous Coating on HFC-245fa Pool Boiling Heat Transfer
Abstract not provided
33 ADVANCED PROPULSION SYSTEMS↗
Safety shutdown separators
The present invention pertains to electrochemical cells which comprise (a) an anode; (b) a cathode; (c) a solid porous separator, such as a polyolefin, xerogel, or inorganic oxide separator; and (d) a nonaqueous electrolyte, wherein the separator comprises a porous membrane having a microporous coating comprising polymer particles which have not coalesced to form a continuous film. This microporous coating on the separator acts as a safety shutdown layer that rapidly increases the internal resistivity and shuts the cell down upon heating to an elevated temperature, such as 110.degree. C. Also provided are methods for increasing the safety of an electrochemical cell by utilizing such separators with a safety shutdown layer.
30 DIRECT ENERGY CONVERSION↗
Nucleate pool boiling of R-245fa at low saturation temperatures for hydrogen precooling applications
In this study, experiments were conducted to measure the pool boiling performance of saturated R-245fa at low saturation temperatures (-30 degrees C, -40 degrees C, and -50 degrees C). Horizontally oriented cylindrical heat sources were used as the test samples and were intended to simulate a small section of a hydrogen-filled tube. Measurements evaluated the effects of saturation temperature and two microporous coatings on heat transfer coefficients (HTC), critical heat flux (CHF), and boiling incipient superheat. Results show that boiling performance decreases as the saturation temperature reduces - a result of less active nucleation sites and higher vapor coverage of the heated surface at lower temperatures. Microporous coatings increased HTCs and CHF values, but did not have a significant effect on reducing the boiling incipient superheat. Finally, the experimental results were used to develop correlations for nucleate pool boiling on plain and microporous surfaces that can be used to predict HTCs and CHF values at low saturation temperature conditions (down to -50 degrees C).
08 HYDROGEN↗
Power Electronics Thermal Control (Presentation)
Thermal management plays an important part in the cost of electric drives in terms of power electronics packaging. Very promising results have been obtained by using microporous coatings and skived surfaces in conjunction with single-phase and two-phase flows. Sintered materials and thermoplastics with embedded fibers show significant promise as thermal interface materials, or TIMs. Appropriatecooling technologies depend on the power electronics package application and reliability.
33 ADVANCED PROPULSION SYSTEMS↗
High Energy Storage Capacity Low Cost Iron Flow Battery
A new flow battery was proposed that utilizes low cost materials: iron as the only active element, cheap aqueous electrolytes, and inexpensive separators. During charging, ferrous iron (Fe 2+ ) is oxidized to ferric iron (Fe 3+ ) at the positive electrode while it (Fe 2+ ) is reduced to form iron metal (Fe 0 ) at the negative electrode. Because iron is plated at the negative electrode during charging, conventional electrode structures couple the energy storage capacity and the power rating of the battery. In order to decouple the energy and power ratings and regain the economic advantages of a flow battery, a slurry electrode design was proposed for use as the negative electrode. The slurry electrode is made by flowing electrically conductive particles in an electrolyte containing the dissolved iron species. On charging, iron is plated onto the particles. The particles can then carry the iron metal out of the cell to be stored in external reservoirs. This project looked to develop a slurry for the negative electrode of the all-iron flow battery that can operate at 200 mA/cm 2 with <100 mV overpotential, be pumped with parasitic energy costs < 10%, and promote plating on the particles. A scalable and stackable cell design of 1100 cm 2 was developed. The project was initially under contract in mid-January 2013. The project was converted from a one-year proof of concept seedling to an additional two-year program, then extended with an 18-month plus-up, and finally with an additional 6-month approved cost-overrun. During the seeding project, the concept of plating on carbon particles in a slurry was demonstrated. However, this was accomplished with high-cost multi-walled carbon nanotubes as the slurry material. The following two-year program discovered several low-cost carbon blacks that could also be used in this application. These findings were supported by an analysis that demonstrated the effectiveness of the carbon that takes into account not just the effective electronic conductivity of the slurry, but also the surface area per volume of the slurry. It was demonstrated that stable, flowable slurries could be created with these carbons, even when the carbons where fully loaded with iron during charging. During the two-year program, laboratory-scale 50 cm 2 single-cells demonstrated charge-discharge cycling at current densities of 150 mA/cm 2 and energy efficiencies of >50%. Meanwhile, cost modeling continued to show promise for this energy storage approach. Following the conversion period, the overall objective of the nominally 18-month plus up period was to close the technical gap of a 25X scale-up and reduce risk to enable commercial investment required to develop a slurry iron flow battery product. A specific objective was to demonstrate 150 cycles of performance exceeding 70% energy efficiency with a 10-cell stack of 1156 cm 2 cells operating at 100 mA/cm 2 . The 10-cell short stack was designed to have a power delivery rating of approximately 1 kW, which represents a size commensurate with the requirements of our commercialization partner at that time. A complete battery support system for the full-size cell was designed, fabricated, and tested. This includes pumps (multiple types were considered, and constant volume hose pumps were found to be acceptable for performance and cost), electrolyte rebalance reactor, and sensors and control systems. The support system proved to be well-behaved and worked well. A new low-cost membrane was developed for this system based on a microporous polymer support with a layer of hydrogel polymer. The membrane had low resistivity, and significantly reduced pressure driven fluid flow across the membrane (as compared to the un-coated microporous support). This membrane approach was scaled-up in conjunction with a commercial toll coating company, and a large amount of membrane was manufactured to support large cell and stack testing. A new concept for an electrolyte rebalance reactor to react hydrogen gas from the negative electrolyte (from plating inefficiency) with excess ferric ion in the positive electrolyte was developed. This design was very simple, low cost, and effective. The full scale 1156 cm 2 single-cell was designed, modeled, fabricated and tested. Modeling showed that uniform flow-distribution should be obtained with the designed flow distributor. The design took into consideration the need to stack the cells, and components were fabricated for a ten-cell stack. Testing of the cell for charge and discharge demonstrated current densities of 50 mA/cm 2 with efficiencies of 50%. However, optimization and long cycling could not be accomplished because the slurry electrode would plug within the cell and block the flow. This would shut down the cell after several charge-discharge cycles. Various approaches were pursued to address this problem with some progress. However, there was not adequate time to find solutions to the problem although several promising approaches were identified for future work. The final deliverable for this proposed 18-month effort was to be a 1 kW, 6 kWh slurry flow battery, with complete balance of plant, ready for testing at an ARPA-E ‘Charges’ site with an estimated capital cost less than $\$ $45/kWh for a six-hour system (excluding power electronics). The deliverable milestone was not achieved for reasons mentioned above related to the slurry plugging. At the completion of this project, it was determined that the cost targets are achievable. The cost estimate for a 1 MW system with a one-hour capacity was estimated at $\$ $140/kWh (including power electronics) and for a six-hour system was estimated at $\$ $40/kWh (including power electronics). These costs include the battery, the balance of plant, the power conditioning and a concrete pad. This program resulted in three patents including the slurry-based iron flow battery, the rebalance reactor, and the membrane separator. At the time of this report, slurry-based iron flow battery patents have been issued in the US, China, Japan, Korea, and Europe. The other patent applications were under various stages of examination. A licensee was identified and the company initiated a scale-up and development program to take this technology to the marketplace, and CWRU staff have transferred their know-how and knowledge base to the company. This technology will enhance the economic and energy security of the United States by enabling the use of intermittent renewable energy technology, such as wind and solar power, as dispatchable resources. This report summarizes the results of this research and development program.
25 ENERGY STORAGE↗
Molecular layer deposition (MLD) modified SSZ-13 membrane for greatly enhanced H 2 separation
Zeolite membranes with high thermal stability and well-fined pores are attractive for gas separation. However, the defects are almost inevitable in zeolite membranes. Moreover, fine-tuning zeolitic pores for precise molecular separation is challenging. In this study, molecular layer deposition (MLD) was employed to deposit ultrathin microporous coating on SSZ-13 zeolite membrane. The MLD modified SSZ-13 composite membrane was highly selective for H 2 separation. With optimized MLD cycles, H 2 /N 2 and H 2 /CH 4 ideal selectivities as high as 35.6 and 427, respectively, were obtained, in strong contrast with approximately 5 for base SSZ-13 membrane. Our results suggest that MLD is a very promising technology to precisely modify the pore size of zeolite membranes, while minimizing flow through non-selective defects, for gas separation.
36 MATERIALS SCIENCE↗
Dispersion controlled by permeable surfaces: surface properties and scaling
Permeable and porous surfaces are common in natural and engineered systems. Flow and transport above such surfaces are significantly affected by the surface properties, e.g. matrix porosity and permeability. However, the relationship between such properties and macroscopic solute transport is largely unknown. In this work, we focus on mass transport in a two-dimensional channel with permeable porous walls under fully developed laminar flow conditions. By means of perturbation theory and asymptotic analysis, we derive the set of upscaled equations describing mass transport in the coupled channel–porous-matrix system and an analytical expression relating the dispersion coefficient with the properties of the surface, namely porosity and permeability. Our analysis shows that their impact on the dispersion coefficient strongly depends on the magnitude of the Péclet number, i.e. on the interplay between diffusive and advective mass transport. Additionally, we demonstrate different scaling behaviours of the dispersion coefficient for thin or thick porous matrices. Our analysis shows the possibility of controlling the dispersion coefficient, i.e. transverse mixing, by either active (i.e. changing the operating conditions) or passive mechanisms (i.e. controlling matrix effective properties) for a given Péclet number. By elucidating the impact of matrix porosity and permeability on solute transport, our upscaled model lays the foundation for the improved understanding, control and design of microporous coatings with targeted macroscopic transport features.
36 MATERIALS SCIENCE↗
Enhancement of Heat Transfer with Pool and Spray Impingement Boiling on Microporous and Nanowire Surface Coatings
The DOE National Renewable Energy Laboratory (NREL) is leading a national effort to develop next-generation cooling technologies for hybrid vehicle electronics. The goal is to reduce the size, weight, and cost of power electronic modules that convert direct current from batteries to alternating current for the motor, and vice versa. Aggressive thermal management techniques help to increase power density and reduce weight and volume, while keeping chip temperatures within acceptable limits. The viability of aggressive cooling schemes such as spray and jet impingement in conjunction with enhanced surfaces is being explored. Here, we present results from a series of experiments with pool and spray boiling on enhanced surfaces, such as a microporous layer of copper and copper nanowires, using HFE-7100 as the working fluid. Spray impingement on the microporous coated surface showed an enhancement of 100%-300% in the heat transfer coefficient at a given wall superheat with respect to spray impingement on a plain surface under similar operating conditions. Critical heat flux also increased by 7%-20%, depending on flow rates.
25 ENERGY STORAGE↗
Ultrathin coatings of nanoporous materials as property enhancements for advanced functional materials.
This report summarizes the findings of a five-month LDRD project funded through Sandia's NTM Investment Area. The project was aimed at providing the foundation for the development of advanced functional materials through the application of ultrathin coatings of microporous or mesoporous materials onto the surface of substrates such as silicon wafers. Prior art teaches that layers of microporous materials such as zeolites may be applied as, e.g., sensor platforms or gas separation membranes. These layers, however, are typically several microns to several hundred microns thick. For many potential applications, vast improvements in the response of a device could be realized if the thickness of the porous layer were reduced to tens of nanometers. However, a basic understanding of how to synthesize or fabricate such ultra-thin layers is lacking. This report describes traditional and novel approaches to the growth of layers of microporous materials on silicon wafers. The novel approaches include reduction of the quantity of nutrients available to grow the zeolite layer through minimization of solution volume, and reaction of organic base (template) with thermally-oxidized silicon wafers under a steam atmosphere to generate ultra-thin layers of zeolite MFI.
12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
Pool Boiling Heat Transfer Characteristics of HFO-1234yf on Plain and Microporous-Enhanced Surfaces
Explore the source record for details and available documents.
33 ADVANCED PROPULSION SYSTEMS↗
Pool Boiling Heat Transfer Characteristics of HFO-1234yf With and Without Microporous-Enhanced Surfaces
Abstract not provided
33 ADVANCED PROPULSION SYSTEMS↗
Enabling low-IrO2 proton exchange membrane water electrolysis via microporous layer-supported catalyst-coated membranes
Not Available
Hansen, Kentaro U.↗
Influence of Ink Formulation and Drying Conditions on Ionomer Distribution in High-Performance Roll-to-Roll-Coated Gas-Diffusion Electrodes
To enable mass production of fuel cell membrane electrode assemblies (MEAs) catalyst layers production will require continuous roll-to-roll (R2R) coating processes. Gas diffusion electrodes (GDEs) are advantageous for mass production because the catalyst layer can be directely coated on the microporous layer of the gas diffusion media without the need for a decal-transfer process. It is known that the water-to-alcohol ratio in the catalyst ink influences the interactions of the ionomer with the catalyst leading to different distributions of ionomer in spray-coated catalyst layers. It is also known that during drying of colloidal mixtures, like fuel cell inks, factors such as drying rate, particle size, and agglomeration influence how the materials distribute themselves throughout the thickness of the dired film. Thus far there have only been limited studies to understand how process conditions such as ink formulation and drying temperature influence the distribution of ionomer and catalyst coated using scalable methods. This understanding is especially important for GDEs since it is known that having a sufficient amount of ionomer at the catalyst layer-membrane interface is critical for high performance. In this study we have focused on determining how the ratio of water to 1-propanol in the catalyst ink ink and drying temperature influence the distribution of ionomer throughout the thickness of the catalyst layer. Using a combination of Kelvin probe and x-ray photoelectron spectroscopy we show that an ionomer-rich surface is promoted by a higher drying rate and a water-rich catalyst ink. In contrast, a 1-propanol catalyst ink leads to a lower concentration of ionomer on the top surface. Using x-ray computed tomography, we are able to characterize the ionomer distribution throughout the thickness of the layer. We find that, in addition to promoting an ionomer-rich top surface, water-rich inks lead to a more homogenous distribution of ionomer, whereas a 1-propanol-rich ink leads to a more irregular distribution. It is found that MEA performance is improved by selecting conditions and ink formulations that promote ionomer enrichment at the top surface to facilitate a good interface with the membrane. MEAs prepared with a 75 wt% water catalyst ink with a 0.9 I/C have equivalent performance to spray-coated GDEs. Critically, these R2R-coated GDEs do not need an additional ionomer overlayer like the spray-coated GDEs do, reducing the number of processing steps in a manufacturing setting. This work shows that with the appropriate selection of materials, ink formulation, and processing conditions gas-diffusion electrodes are a viable pathway for fuel cell manufacturing.
ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION↗
Efficient Solar‐Thermal Distillation Desalination Device by Light Absorptive Carbon Composite Porous Foam
Abstract Solar‐thermal driven desalination based on porous carbon materials has promise for fresh water production. Exploration of high‐efficiency solar desalination devices has not solved issues for practical application, namely complicated fabrication, cost‐effectiveness, and scalability. Here, direct solar‐thermal carbon distillation (DS‐CD) tubular devices are introduced that have a facile fabrication process, are scalable, and use an inexpensive but efficient microporous graphite foam coated with carbon nanoparticle and superhydrophobic materials. The “black” composite foam serving as a solar light absorber heats up salt water effectively to produce fresh water vapor, and the superhydrophobic surface of the foam traps the liquid feed in the device. Two proof‐of‐principle distillation systems are adopted, i.e., solar still and membrane distillation and the fabricated devices are evaluated for direct solar desalination efficiency. For the solar still, nanoparticle and fluorosilane coatings on the porous surface increase the solar energy absorbance, resulting in a solar‐steam generation efficiency of 64% from simulated seawater at 1 sun. The membrane distillation demonstrates excellent vapor production (≈6.6 kg m ‐2 h ‐1 ) with >99.5% salt rejection under simulated 3 sun solar‐thermal irradiation. Unlike traditional solar desalination, the adaptable DS‐CD can easily be scaled up to larger systems such as high‐temperature tubular modules, presenting a promising solution for solar‐energy‐driven desalination.
42 ENGINEERING↗
The influence of electrode crack dimensions on the durability of polymer electrolyte membrane fuel cells
Electrode cracks in polymer electrolyte membrane fuel cells (PEMFCs) are correlated with early onset failures. Here, in this work we investigate the influence of cracked gas diffusion electrodes (GDEs) on the durability of the membrane electrode assembly (MEA) using a combined chemical-mechanical accelerated stress test (AST). Electrode crack dimensions were systematically tuned using ink formulations and material selection strategies. A parameter to describe the crack width areal density (Φ CW ) was used to quantify the degree of discontinuity in the electrode surfaces. Open circuit voltage (OCV) transient analyses were used to benchmark and characterize the failure mechanisms in the MEAs as a function of the Φ CW . While smaller electrode-level cracks, on the order of microns, yielded a 28 % decrease in operating lifetime, larger cracks that propagated from a discontinuous, microporous layer (MPL) coating, decreased the operating lifetime by 56 %. This work emphasizes the need for material processing strategies that consider defect tolerances to limit membrane failures in PEMFCs.
08 HYDROGEN↗
Characterization of Microstructure and Wear Resistance of PEO Coatings Containing Various Microparticles on Ti6Al4V Alloy
Titania-based composite coatings were prepared by plasma electrolytic oxidation (PEO) treatment of Ti6Al4V alloy in electrolyte with α-Al{sub 2}O{sub 3}, Cr{sub 2}O{sub 3} or h-BN microparticles in suspension. The microstructure, composition of PEO composite coatings were analyzed by SEM, EDS and XRD. The wear resistance of composite ceramic coatings was studied by ball-on-disk wear test at ambient temperature and 300 °C. The results showed that the addition of microparticles accelerated the growth rate of PEO coating and changed the microstructure and composition of PEO coating. PEO coating was porous and mainly composed of rutile-TiO{sub 2}, anatase-TiO{sub 2} and Al{sub 2}TiO{sub 5}. PEO/α-Al{sub 2}O{sub 3} (Cr{sub 2}O{sub 3} or h-BN) composite coating only had small micropores and appeared some α-Al{sub 2}O{sub 3} (Cr{sub 2}O{sub 3} or h-BN) phase. Besides, the addition of α-Al{sub 2}O{sub 3} (Cr{sub 2}O{sub 3} or h-BN) microparticles greatly improved the wear resistance of PEO coating. At ambient temperature, abrasive wear dominated the wear behavior of PEO coating, but abrasive wear and adhesive peel simultaneously happened at 300 °C. Whether at ambient temperature or 300 °C, PEO composite coating had better wear resistance than PEO coating. Besides, PEO/h-BN composite coating outperformed other composite coatings regardless of the temperature.
36 MATERIALS SCIENCE↗
Experimental and computational study of the microporous layer and hydrophobic treatment in the gas diffusion layer of a proton exchange membrane fuel cell
Enabling fuel cell operation at high current density is critical for developing competitive alternative power system to replace internal combustion engine. However, liquid water management continues to be a challenge for high humidity or high current density operation. Water condensation in the porous media hinders efficient oxygen transport to the catalyst layer, which in turns, reduces fuel cell performance. To improve water management capability, the gas diffusion layer is often impregnated with Polytetrafluoroethylene (PTFE) and coated with a thin microporous layer, which have shown to improve fuel cell performance, especially under wet conditions. However, the fundamental mechanism that drives the performance enhancement is still not well understood. In this work, the effects of PTFE impregnation and MPL were studied using both experimental and computational techniques. Both limiting current and polarization tests under dry and wet operating condition are conducted to study the oxygen transport resistance and fuel cell performance. In addition, a 2-D, two-phase, multi-physics PEMFC model is developed to simulate performance and gain a fundamental understanding of local water saturation and oxygen concentration. The combined results show that 5 wt% PTFE impregnation with MPL significantly enhances liquid water management, which enables higher current density operation of a fuel cell.
25 ENERGY STORAGE↗