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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
NASA NTRS1980

Applications of thermal energy storage to waste heat recovery in the food processing industry

A study to assess the potential for waste heat recovery in the food industry and to evaluate prospective waste heat recovery system concepts employing thermal energy storage was conducted. The study found that the recovery of waste heat in canning facilities can be performed in significant quantities using systems involving thermal energy storage that are both practical and economical. A demonstration project is proposed to determine actual waste heat recovery costs and benefits and to encourage system implementation by the food industry.

Wojnar, F.↗
NASA NTRS1978

Thermal energy storage for industrial waste heat recovery

The potential is examined for waste heat recovery and reuse through thermal energy storage in five specific industrial categories: (1) primary aluminum, (2) cement, (3) food processing, (4) paper and pulp, and (5) iron and steel. Preliminary results from Phase 1 feasibility studies suggest energy savings through fossil fuel displacement approaching 0.1 quad/yr in the 1985 period. Early implementation of recovery technologies with minimal development appears likely in the food processing and paper and pulp industries; development of the other three categories, though equally desirable, will probably require a greater investment in time and dollars.

Hoffman, H. W.↗
NASA NTRS1983

Waste heat recovery from adiabatic diesel engines by exhaust-driven Brayton cycles

An evaluation of Bryton Bottoming Systems (BBS) as waste heat recovery devices for future adiabatic diesel engines in heavy duty trucks is presented. Parametric studies were performed to evaluate the influence of external and internal design parameters on BBS performance. Conceptual design and trade-off studies were undertaken to estimate the optimum configuration, size, and cost of major hardware components. The potential annual fuel savings of long-haul trucks equipped with BBS were estimated. The addition of a BBS to a turbocharged, nonaftercooled adiabatic engine would improve fuel economy by as much as 12%. In comparison with an aftercooled, turbocompound engine, the BBS-equipped turbocharged engine would offer a 4.4% fuel economy advantage. If installed in tandem with an aftercooled turbocompound engine, the BBS could effect a 7.2% fuel economy improvement. The cost of a mass-produced 38 Bhp BBS is estimated at about $6460 or 170/Bhp. Technical and economic barriers that hinder the commercial introduction of bottoming systems were identified. Related studies in the area of waste heat recovery from adiabatic diesel engines and NASA-CR-168255 (Steam Rankine) and CR-168256 (Organic Rankine).

Khalifa, H. E.↗
NASA NTRS1978

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

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

Katter, L. B.↗
NASA NTRS1978

Thermal energy storage for industrial waste heat recovery

Thermal energy storage systems designed for energy conservation through the recovery, storage, and reuse of industrial process waste heat are reviewed. Consideration is given to systems developed for primary aluminum, cement, the food processing industry, paper and pulp, and primary iron and steel. Projected waste-heat recovery and energy savings are listed for each category.

Hoffman, H. W.↗
NASA NTRS1983

Applications guide for waste heat recovery

The state-of-the-art of commercially available organic Rankine cycle (ORC) hardware from a literature search and industry survey is assessed. Engineering criteria for applying ORC technology are established, and a set of nomograms to enable the rapid sizing of the equipment is presented. A comparison of an ORC system with conventional heat recovery techniques can be made with a nomogram developed for a recuperative heat exchanger. A graphical technique for evaluating the economic aspects of an ORC system and conventional heat recovery method is discussed: also included is a description of anticipated future trends in organic Rankine cycle R&D.

Moynihan, P. I.↗
NASA NTRS1985

Two-Phase Wet/Dry Engine for Waste-Heat Recovery

Novel supersonic fluid expansion nozzle used to vaporize toluene (or other drying-type organic liquid) by expansion through two-phase region to drive impulse turbine in Rankine-cycle engine.

Elliott, D. G.↗
NASA NTRS1985

Comparative evaluation of three alternative power cycles for waste heat recovery from the exhaust of adiabatic diesel engines

Three alternative power cycles were compared in application as an exhaust-gas heat-recovery system for use with advanced adiabatic diesel engines. The power cycle alternatives considered were steam Rankine, organic Rankine with RC-1 as the working fluid, and variations of an air Brayton cycle. The comparison was made in terms of fuel economy and economic payback potential for heavy-duty trucks operating in line-haul service. The results indicate that, in terms of engine rated specific fuel consumption, a diesel/alternative-power-cycle engine offers a significant improvement over the turbocompound diesel used as the baseline for comparison. The maximum imporvement resulted from the use of a Rankine cycle heat-recovery system in series with turbocompounding. The air Brayton cycle alternatives studied, which included both simple-cycle and compression-intercooled configurations, were less effective and provided about half the fuel consumption improvement of the Rankine cycle alternatives under the same conditions. Capital and maintenance cost estimates were also developed for each of the heat-recovery power cycle systems. These costs were integrated with the fuel savings to identify the time required for net annual savings to pay back the initial capital investment. The sensitivity of capital payback time to arbitrary increases in fuel price, not accompanied by corresponding hardware cost inflation, was also examined. The results indicate that a fuel price increase is required for the alternative power cycles to pay back capital within an acceptable time period.

Bailey, M. M.↗
NASA NTRS1939

Experiments on the Recovery of Waste Heat in Cooling Ducts, Special Report

Tests have been conducted in the N.A.C.A. full-scale wind tunnel to investigate the partial recovery of the heat energy which is apparently wasted in the cooling of aircraft engines. The results indicate that if the radiator is located in an expanded duct, a part of the energy lost in cooling is recovered; however, the energy recovery is not of practical importance up to airplane speeds of 400 miles per hour. Throttling of the duct flow occurs with heated radiators and must be considered in designing the duct outlets from data obtained with cold radiators in the ducts.

Silverstein, Abe↗
NASA NTRS1986

Rotorcraft propulsion for year 2000 plus

The objective of this study was to identify high-payoff technologies for year 2000 small gas turbine engines for rotorcraft application. A current state-of-the-art technology Allison gas turbine engine was used as a baseline and three advanced concepts were studied: the simple cycle engine, a waste heat recovery cycle, and a wave rotor engine cycle. For the simple cycle engine, two general arrangements were considered: the traditional concentric spool arrangement and a nonconcentric spool arrangement. Both a regenerative and a recuperative cycle were studied for the waste heat recovery cycle. An extensive cycle optimization procedure was performed for each configuration under study using relative direct operating cost (DOC) as the figure of merit. A high pressure ratio nonconcentric engine provided the greatest reduction in DOC with a 16.5 percent improvement.

Larkin, T. R.↗
NASA NTRS1986

Small Engine Component Technology (SECT) study

The objective of this study is to identify high payoff technologies for year 2000 small gas turbine engines, and to provide a technology plan to guide research and technology efforts toward revolutionizing the small gas turbine technology base. The goal is to define the required technology to provide a 30 percent reduction in mission fuel burned, to reduce direct operating costs by at least 10 percent, and to provide increased reliability and durability of the gas turbine propulsion system. The baseline established to evaluate the year 2000 technology base was an 8-passenger commercial tilt-rotor aircraft powered by a current technology gas turbine engine. Three basic engine cycles were studied: the simple cycle engine, a waste heat recovery cycle, and a wave rotor engine cycle. For the simple cycle engine, two general arrangements were considered: the traditional concentric spool arrangement and a nonconcentric spool arrangement. Both a regenerative and a recuperative cycle were studied for the waste heat recovery cycle.

Larkin, T. R.↗
DOE OSTI2025

From Theory to Practice: Feasibility Study of a Thermal Microgrid at a DoD Installation: Preprint

Advanced district thermal energy systems, also known as thermal microgrids, can electrify and decarbonize urban districts in a highly efficient way, but adoption of such systems, especially in the US, has been slow. Thermal microgrids use a network circulating water at near-ambient (60-80 degree F) (15- 25 degree C) temperatures, and water-source heat pumps at connected buildings to boost or lower the temperature for space conditioning and domestic hot water. Addressing challenges related to retrofits of existing buildings for integration with such systems, as well as quantifying the benefits of different configurations, will be key to unlocking the full potential of thermal microgrids for energy savings, decarbonization, and resiliency. This paper will do that, by reporting on preliminary results from a feasibility study of a thermal microgrid, and illustrating the process of conceptual design to seek the best possible performance, within the many constraints of existing buildings. The feasibility study focuses on a cluster of existing buildings, including a grocery store, big box style retail store, motel, and clinic, at a US Department of Defense installation in Germany. The study will assess the performance of a pilot-scale thermal microgrid serving those buildings, in terms of energy, emissions, and life cycle cost, and assess practical considerations (such as building retrofits and scalability) for future implementation. A significant opportunity exists for waste heat recovery from refrigeration at the grocery store (more than offsetting the entire building s space heating load in terms of waste heat availability), and modeling of the proposed thermal microgrid will assess the benefits of the waste heat integration. The moderate operating temperatures of thermal microgrids facilitate the integration of waste heat from a variety of sources, and the networks allow waste heat to be shared amongst buildings in proximity. Along with results on expected energy and emissions performance, as well as waste heat integration, the paper will assess implications of load diversity on system performance. The paper will also discuss the process of evaluating existing building HVAC systems for compatibility with a thermal microgrid, including the feasibility of lower heating hot water temperatures compatible with currently-available water-to-water heat pumps. The cluster of buildings under consideration in this study has much in common with commercial buildings in the United States. The process of and results from this feasibility study can inform assessment of the potential for thermal microgrids in other locations and help unlock the benefits of such systems for decarbonization and energy savings.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2026

Application of Ibuprofen Sodium Dihydrate for Thermochemical Energy Storage

Thermochemical energy storage (TCES) offers a transformative approach to address grid instability by harnessing reversible chemical reactions for efficient heat storage and release. Here, we introduce pharmaceutical organic salt hydrates as a class of materials with exceptional performance for low-grade waste heat recovery. We demonstrate ibuprofen sodium dihydrate (ISD) as an example organic hydrate exhibiting a dehydration temperature range of 60-110 °C and a remarkable dehydration enthalpy of up to 59.5 kJ/mol of water, ideally suited for capturing industrial and residential waste heat. Using rigorous multimodal characterization, including thermogravimetric analysis, differential scanning calorimetry, in-situ FTIR, in-situ PXRD, and NMR, we demonstrate ISD's superior thermal, chemical, and structural stability over 150 hydration-dehydration cycles, achieving an unprecedented cycling efficiency of ~99.9%. Compared to conventional inorganic salt hydrates like strontium chloride hexahydrate and calcium oxalate monohydrate, ISD showcases enhanced durability without deliquescence or pulverization, even under high-humidity conditions. In-situ analyses confirm the transition from ISD to ibuprofen sodium anhydrous (ISA) proceeds with structural reorganization, thereby combining the dehydration mechanism with phase transitions, resulting in higher energy storage capacity. Microstructural analyses reveal that repeated water intercalation and structural transitions aid in creating significant porosity that enhances water transport kinetics, further improving the hydration/dehydration performance. By combining the phase change and chemical dehydration mechanisms, ISD paves the way for designing a new class of organic salt hydrates, offering tunable properties to meet diverse thermal energy storage demands and supporting sustainable grid resilience.

Thangaraj, Kavin C.↗
DOE OSTI2025

Thermomagnetic generators for ultra-low-grade marine thermal energy harvesting

Low-grade thermal gradients in marine environments represent an underexploited energy source for autonomous sensing and monitoring. Converting such small temperature differences into usable electrical power remains a key challenge for ocean-deployed systems. We present a deployable thermomagnetic generator thoroughly characterized for marine-relevant energy harvesting. The device powers an internet-connected sensor and harvests ultra-low temperature differences akin to those at the ocean surface. It draws heat from water and rejects it to ambient air, operating optimally at a temperature difference (ΔT) of ~7.5 °C. Laboratory prototypes generated up to 6.7 mW at ΔT ~ 10 °C with gentle airflow (~1 m s -1 ). A separate controlled wave-tank demonstration validated stable operation and sensor powering under marine-like boundary conditions. Given its voltage and power margins, the generator could sustain multiple sensor nodes. Scalability and material assessments identify modular deployment and non-rare-earth alternatives as pathways toward practical marine energy harvesting and low-grade waste-heat recovery.

16 TIDAL AND WAVE POWER↗
DOE OSTI2024

Large Area Near‐Field Thermophotovoltaics for Low Temperature Applications

Abstract Thermophotovoltaics, devices that convert thermal infrared photons to electricity, offer a key pathway for a variety of critical renewable energy technologies including thermal energy storage, waste heat recovery, and direct solar‐thermal power generation. However, conventional far‐field devices struggle to generate reasonable powers at lower temperatures. Near‐field thermophotovoltaics provide a pathway to substantially higher powers by leveraging photon tunneling effects. Here a large area near‐field thermophotovoltaic device is presented, created with an epitaxial co‐fabrication approach, that consists of a self‐supported 0.28 cm 2 emitter‐cell pair with a 150 nm gap. The device generates 1.22 mW at 460 °C, a 25‐fold increase over the same cell measured in a far‐field configuration. Furthermore, the near‐field device demonstrates short circuit current densities greater than the far‐field photocurrent limit at all the temperatures tested, confirming the role of photon tunneling effects in the performance enhancement. Modeling suggests several practical directions for cell improvements and further increases in power density. These results highlight the promise of near‐field thermophotovoltaics, especially for low temperature applications.

36 MATERIALS SCIENCE↗
DOE OSTI2026

Revolutionizing thermal Management in Next-Generation AI data centers: Challenges and breakthrough innovations

Data centers (DCs) serve as critical infrastructure for powering the growth and evolution of AI. Next-generation AI DCs present unique challenges in thermal management driven by unprecedented computational demands. This paper provides a comprehensive summary of key stakeholder perspectives on technology gaps, infrastructure requirements, test bed needs, emerging opportunities, and preliminary solutions related to thermal management for AI DCs. It establishes six strategic pillars of thermal management for next generation AI DC: reliability, deployability, efficiency, resilience, measurability, and valorization. The discussion spans a range of critical topics, including advanced cooling technologies, thermal strategies for emerging modular and edge DCs, system-level optimization and control frameworks, infrastructure planning and grid integration designs, benchmarking approaches, and pathways for waste heat recovery and reuse. The proposed research, development, and demonstration efforts are aimed at accelerating the deployment of AI DCs while ensuring energy efficiency, reliability, safety, and regulatory compliance.

Wang, Pengtao [ORNL] (ORCID:0000000214713429)↗
DOE OSTI2025

Nature-inspired lotus-shaped fins combined with hybrid nanoparticles and metal foam for high-performance latent heat thermal energy storage

Latent heat thermal energy storage (LHTES) systems play a critical role in renewable energy integration by providing high energy density and nearly isothermal operation during phase transitions. However, their performance is often limited by slow melting/charging rates, which motivates the search for enhanced heat transfer designs. This study investigates the melting behavior of RT-82 phase change material (PCM) using novel lotus-shaped fins combined with copper metal foam and conductive graphene nanoparticles and carbon nanotubes. A two-dimensional enthalpy-porosity model in ANSYS Fluent was developed to simulate the charging/melting process, capturing non-thermal equilibrium between the foam and PCM/nano-PCM. In this study, effects of fin geometry, nanoparticle concentration, and foam porosity on melting dynamics and cost-performance trade-offs were investigated. Results showed that natural convection accelerated melting by ~12% compared to conduction-only scenarios. Optimized lotus-shaped fins with higher fin density (T3F4 and T3F10) achieved up to 63% faster melting relative to sparse configurations. Graphene nanoparticles improved thermal conductivity, with a 6% volume fraction, by reducing melting time by ~6.9%, while their combination with 75% porosity foam achieved a maximum reduction in the melting time of ~51% compared to pure PCM. Cost-performance analysis identified T3F4 as the most balanced design, offering rapid thermal response without excessive material costs, while moderate-density designs like T3S6 provided economical alternatives with acceptable performance. These results highlight the performance enhancement that can be achieved by integrating bio-inspired fins, nanoparticles, and foams, into compact and efficient LHTES for solar heating, building thermal management, and industrial waste-heat recovery applications.

25 ENERGY STORAGE↗
DOE OSTI2024

Enhanced power density in zero-vacuum-gap thermophotovoltaic devices

Thermophotovoltaic (TPV) devices, which convert infrared thermal radiation from a hot emitter into electricity, hold great promise for applications in energy storage and waste heat recovery. While recent advancements have developed TPV devices with high efficiency, much less attention has been focused on improving the power density. Current TPV methods face challenges in significantly boosting the power density using emitters at very high temperatures (>2000 °C) or using complex, costly architectures such as near-field TPV. Here, we present the first experimental demonstration of a novel far-field TPV concept called “zero-vacuum-gap TPV” that eliminates the vacuum or gas-filled gap in conventional designs. By incorporating a high-index, infrared-transparent, and thermally insulating fused quartz spacer, we achieved a two-fold increase in power density compared to the far-field counterpart under identical conditions. Notably, in our experiment, the zero-vacuum-gap far-field design transforms a less-optimized, low-power-density far-field device into one with one of the highest power densities reported at moderate temperatures (700–1100 °C). Moreover, our measurements using a graphite emitter surpass the blackbody limit for gap-integrated far-field devices and match the performance of near-field TPV devices with an ultrathin 200-nm gap. Our findings suggest that zero-vacuum-gap TPV offers potential for cost-effective, scalable manufacturing using current technologies. Additionally, our modelling predicts that further power enhancements over one order of magnitude are possible with other spacer materials.

14 SOLAR ENERGY↗