Acoustical ceiling tiles are formed as a mixture of water, starch, clay and mineral fibers with high initial water content. The water is initially removed from the wet tile by physical methods and, then, the tile is subject to long convective drying in a high temperature kiln. The development of a numerical model describing the ceiling tile kiln operation is proposed in this work with the overall goal to optimize energy efficiency and drying time, to improve process control, and to increase productivity of the drying process.

A number of coatings are applied on tile boards during the manufacturing process. Convective and infrared drying methods and their combinations are currently employed to dry the various coatings. The major requirements to the drying process include short drying times, energy efficiency, and full control of the drying process. Currently used drying processes have low turn down ratios, often result in overheating and damage of the boards, have low flexibility, and require complex control approaches. The drying optimization in terms of efficiency and processing time can be achieved by numerical modeling of the drying process. The development of numerical model describing heat and mass transfer in the tile coatings is proposed in this work with the overall goal to optimize energy efficiency, drying times, and process control.

Composite construction panels are manufactured from a specially engineered combination of synthetic gypsum and cellulose fibers to offer superior durability and water-resistance. The formed wet panels are died up in a convective cross-flow kiln that has a capability to control independently firing rates and airflow rates for multiple drying zones. We propose to perform numerical and experimental studies on cross-flow kiln drying of the panels with overall aim to optimize the drying performance, energy efficiency and product characteristics.

To meet the challenging goals of the ARPA-E GENSETS FOA, a research team of NanoConversion Technologies, Gas Technology Institute, GE Appliances, and NC State University proposes to combine high-efficiency gas burner technology with a radical new electrochemical heat engine in a low cost natural gas appliance. A research group from NC State University has a strong background in superadiabatic combustion and will participate in development of compact high-efficiency low emission burner. Excess enthalpy or superadiabatic flames in porous media allows stable burning far beyond the conventional flammability limits. By recuperating the heat released in a porous medium, stable combustion can be attained in a wide range of equivalence ratios. As an example, very lean mixtures can be burned in the excess enthalpy flames to minimize pollution and reduce greenhouse effects. Heat regeneration in the porous matrix and low thermal non-equilibrium between the gas and the solid phases reduces combustion temperatures limiting thermal NOx production to extremely low levels.

Modern demands imposed on energy efficiency and variety of natural gas mixtures used today for energy generation call for development of novel methods for characterization of fuel properties. The uncontrolled fuel composition changes lead to variation of flame structure and stability, enhanced generation of NOx and soot, change in the heating value and process efficiency. Novel real-time methods of fuel characterization are currently under development and spectroscopic methods are among them. Spectroscopic Gas Quality Sensor for characterization of opportunity fuels is proposed for further development and commercialization.

Due to low cost, simple design, and multiple functionality ribbon burners remain a workhouse r in many industries using natural gas for heating and processing applications. Recently, increasingly stringent air emission regulations were introduced that target pollution emissions from combustion systems. In particular, significant reductions in atmospheric discharge of nitrous oxides are expected to be implemented in a near future. Current ribbon burner designs do not meet these emission standards. Successful development of NOx minimization strategies will enable wide continuous applications of ribbon burners by industrial users. It will also allow the natural gas combustion utilizing industries to stay compliant with the new regulations.

Increasingly stringent air emissions and efficiency regulations will require significant reductions in atmospheric discharge of greenhouse gases primarily carbon dioxide, methane, and nitrous oxide. Excess enthalpy porous bed combustion frequently referred to as superadiabatic combustion has the potential to significantly reduce NOx and CO2 emissions by reducing peak flame temperatures and increasing efficiency. Successful development of the excess enthalpy combustion systems will enable the natural gas combustion utilizing industries to stay compliant with the new regulations and will enable industrial users of natural gas to remain competitive while continuing to burn natural gas for process heat.

Rapid development of novel combustion technologies imposes special requirements on diagnostic and control methods used. At present, the chemical composition of combustion gases is usually measured only in the exhaust stream providing average information on the performance of the combustion process. To maximize efficiency, while keeping emissions low, requires real-time information about the performance of each burner and/or spatial characteristics of the complex geometry flames. Industrial combustion and gasification processes will enormously benefit from novel 2-D sensors utilizing imaging techniques to map the flame species and defining the flame zones responsible for pollutant formation and efficiency losses. This project is further development and demonstration of the sensor technology developed under the "Optical Diagnostics of Gasifier Flames". Work will begin with modification of the sensor software to enable real time temperature data acquisition, processing and providing the obtained gasifier temperature information to the gasifier operators. The second project task will focus on the sensor hardware modifications needed to improve optical reliability of the sensor system.

Hydrogen is the most coveted and cleanest of all fuels. Yet it is also very expensive, since it is obtained at an industrial scale only through natural gas, oil, or coal. In addition to being expensive, these hydrocarbon sources of hydrogen also release significant carbon dioxide emissions. The alternative of recovering hydrogen from H2S would be at the very least free and carbonless. In 2011 the National Science Foundation awarded a Phase II grant to Innovative Energy Solution. A numerical modeling is proposed to understand the complex reaction chemistry, heat transfer, and flow pattern occurring in the reactor. Numerical studies will be conducted based upon computational model of ultrarich superadiabatic flames formed in linear and cyclic flow reactors. Superadiabatic partial oxidation of an ultrarich H2S/oxidizer mixture will be represented within one-dimensional, unsteady model. The flame, treated in a volume-averaged approach, will be considered isobaric, and one-dimensional. The model, incorporating a comprehensive heat transfer mechanisms, will help in optimizing the reactor.

The main objective of this collaborative research proposal between teams at the University of Oklahoma (OU) and North Carolina State University (NCSU) is to achieve controlled synthesis of TMO nanoforms and to develop a scientific understanding of the underlying mechanisms. Following the successful preliminary experiments, the proposed research will extend the method to various important transition metals, such as molybdenum, tungsten, iron, niobium, tantalum, chromium, vanadium, and zinc, to produce an experimental database on generated nanoforms and corresponding synthesis conditions. The focus of the proposed studies will be the confirmation of the key hypothesis that various 1-D TMO nanostructures can be generated in flames by a synergetic action of a highly reactive flame environment possessing strong thermal and chemical gradients. Within the collaborated research efforts, OU team will study the structure and morphology of generated nanoforms that will be analyzed using advanced material diagnostic techniques and NCSU group will conduct flame diagnostics and modeling to uncover the mechanisms controlling the formation of nanostructured TMOs. Special attention will be given to the study of the flame chemistry, the nature of flame interaction with the metal surfaces, and the mechanism of the synthesis process. The proposed research will serve as a fundamental basis for the development of novel technologies for flame synthesis of advanced TMO nanostructures with potential applications in electronics, medicine, chemistry, optics, sensors, recording and imaging media. The advantages of flame synthesis over other synthesis methods involve reduced cost, shorter processing times, improved scalability and quality. The proposed method suggests essential economic and technological advances over current synthesis methods as well as the very significant social impact of the research.