ROCKLEDGE, FL – December 21, 2009 – Mainstream Engineering Corporation (MEC), a leading research and development company specializing in thermal control and energy conversion, has been awarded a contract from the U.S. Navy’s Office of Naval Research to study oxygen-enriched flames with JP-8, a kerosene-based fuel used by the military for all engines, stoves and burners. MEC is collaborating on this program with Prof. Daniel Kirk of the Florida Institute of Technology (Melbourne, FL), who is the lead institution for the project.

Oxygen-enriched combustion is expected to substantially improve the performance of MEMS-based micro-combustors needed for micropower generation. A solid fundamental understanding of oxygen-enriched combustion chemistry and the associated flame properties, such as flame speed, is needed to push the development of these power systems forward. This fundamental understanding is now sorely lacking. For example, existing combustion reaction mechanisms, which are generally tailored for combustion in ambient air, do not predict the correct flame speed trends for even the simplest hydrocarbon fuels in oxygen-enriched air.

This study will experimentally investigate the flame structure, flame speed, flammability limits, quenching distance, and thermo-acoustic noise of premixed, oxygen-enriched flames of JP-8 and a well-established surrogate. The measured data will be used to construct and validate a skeletal reaction mechanism for the combustion of the JP-8 surrogate (n-decane) under elevated oxygen concentrations. The reaction mechanism will then be used to design an oxygen-enriched, micro-scale combustor for MEMS power generation.

Oxygen-enriched micro-combustors have the potential for compatibility with logistics fuels and elimination of the need for expensive platinum catalysts. This research program will provide the data and mechanistic understanding needed for the development of these devices. This project supports the Navy’s efforts to increase freedom-of-action and operational effectiveness through efficient power systems.

ROCKLEDGE, FL – November 24, 2009 – Mainstream Engineering Corporation, a leading research and development company specializing in advanced thermal control and energy conversion, has been awarded a contract from the U.S. Navy to Develop a Thermal Management System for Tactical Airborne High Power Laser Applications.

Current aircraft thermal management systems are not capable of dissipating high-heat-flux thermal loads or transporting and rejecting overall thermal loads of those associated with tactical lasers. The proposed thermal management system must overcome the limitations of existing systems as well as meet the strict volume, mass and reliability requirements of aircraft operation. To meet these requirements, Mainstream will leverage its extensive experience in high-heat-flux technologies and advanced thermal management system development.

In the first phase of this effort, Mainstream will complete both an analytical evaluation of candidate high-heat-flux cooling technologies and system architectures for an airborne tactical fiber laser system as well as conduct an experimental evaluation of a sub-scale thermal management system. The experimental evaluation will demonstrate the ability of the high-heat-flux cooling configuration to acquire, transport and reject the thermal loads from various laser components. Following this effort, Mainstream will design the complete, full-scale laser thermal management system and demonstrate the system’s performance with the actual laser components.

ROCKLEDGE, FL – October 26, 2009 – Mainstream Engineering Corporation has been awarded a Phase I SBIR contract from the U.S. Navy to demonstrate the effectiveness of hydrothermal liquefaction and compaction in the rapid reduction of waste onboard ships.

General shipboard operations produce large amounts of waste such as food waste, cardboard, plastic and glass on a daily basis. This solid waste must either be eliminated or placed in a designated location that occupies valuable cargo space. Furthermore, this waste storage can lead to objectionable odors, attract unwanted pests and spread pathogens.

Hydrothermal liquefaction is a process that converts a large portion of the organic content of ship waste into an alternative fuel, which can be used on site to produce power and electricity. This process combined with a compactor will reduce the overall volume of the waste and create additional cargo space.

Mainstream plans to use a batch reactor to demonstrate the feasibility of the hydrothermal liquefaction process to produce fuel from a heterogeneous waste stream. The resulting fuel will be tested to determine its properties and potential applications. Mainstream will also design a continuous hydrothermal liquefaction and compaction system capable of processing a larger portion of the waste produced daily on ships.

ROCKLEDGE, FL – September 9, 2009 – Mainstream Engineering Corporation, has been awarded a Phase II SBIR contract from the U.S. Air Force to develop a portable fluidized-bed reactor for flash pyrolysis of landfill waste.

The Main Base Landfill at Edwards Air Force Base will reach full capacity by no later than 2017, and many other landfills across the country are facing the same situation. Waste streams need to be redirected to extend the lives of these facilities. An ideal solution to the problem is to reduce the volume of waste while producing an alternative fuel.

During the Phase I effort, Mainstream demonstrated that a portable, flash-pyrolysis, fluidized-bed reactor could significantly reduce the amount of biomass material entering the landfill and produce a useful liquid fuel. In Phase II, Mainstream plans to design, build, and fully characterize a continuous pilot-scale flash-pyrolysis reactor capable of converting 35 kg/hr of greenwaste into bio-oil. Upgrading the raw bio-oil produced to improve its stability, miscibility, and materials compatibility will also be investigated.

ROCKLEDGE, FL – July 30, 2009 -Mainstream Engineering Corporation has been awarded a Phase II contract from the Army to Develop a Temperature Controlled Human Remains Transfer Case (TCHRTC).

The Vietnam-era method of preserving human remains by packing them inside an aluminum transfer case with 40-60 pounds of ice is still done today. Given that internal air temperature is not controlled or monitored and transport can last at least 10 hours, proper storage temperature cannot be maintained.

During Phase I of this Army contract, Mainstream developed and tested a full-size, operational prototype of a TCHRTC. This human remains transport case provides uninterrupted, accurate temperature control from either internal or external power sources, while meeting cost, size, weight, and reliability requirements. Internal power is supplied from common, easily replaceable, nickel-metal-hydride or lithium-ion batteries located in the electronics box. In the Phase II effort, Mainstream engineers will optimize the design, perform extensive testing, and manufacture production-quality prototypes for field testing and evaluation by Army personnel. At the conclusion of this Phase II contract, production-quality TCHRTCs will be available to the military for sale.

ROCKLEDGE, FL – July 15, 2009 – Mainstream Engineering Corporation, a leading research and development company specializing in advanced thermal control and energy conversion, has been awarded a contract from DARPA to develop a linear free piston generator.

DARPA has the need to develop small (10 hp), modular engines with a very high power density (>1hp/lb), thermal efficiencies higher than 25%, quiet operation, and the ability to run on JP-8. Reciprocating engines and gas turbines are proven technologies; however, they have limitations that prevent them from reaching all of the performance targets. A linear free piston engine (LFPE) has the possibility to achieve all of the performance criteria. The LFPE has all of the benefits of a diesel engine while eliminating the rotating machinery and reducing the size of the “crankcase”. This simplification reduces the weight and therefore increases the power density. Mainstream will apply new features to increase and control the operating speed, which has been the largest technical challenge remaining for this type of engine. Mainstream is in an optimal position to develop the LFPE for this application as Mainstream has the necessary experience, facilities, and complementary programs to develop many of the necessary components.

ROCKLEDGE, FL – July 1, 2009 – Mainstream Engineering Corporation, a leading research and development company specializing in advanced thermal control and energy conversion, has been awarded a contract from the U.S. Army to demonstrate a local hotspot cooling with a digital microfluidics device with enhanced nanostructures.

The U.S. Army wishes to incorporate an ultra high efficiency heat dissipation system for power inverters on off-road vehicles that can have locally very high heat fluxes. Mainstream will develop a digital microfluidics device to satisfy this need. This device will use electric fields to move droplets over surfaces hydrophobized by microstructures. The enhanced hydrophobized surface reduces drag and therefore increases the heat removal rate and decreases the voltage required for motion. This novel approach produces a cooling system that does not have a pump or compressor needed to drive a working fluid, and thus the thermal efficiency can be extremely high for this device.

Previous experimental and thin films fabrication techniques will be employed to first establish the operational limits of the devices, including the droplet motion onset voltage, the droplet speed, and the effective heat transfer rate to the droplets. A prototype system will be made and simulated with the same heat loads as those found on power inverters for off-road military vehicles.

ROCKLEDGE, FL – May 28, 2009 – Mainstream Engineering Corporation, a leading research and development company specializing in advanced thermal control and energy conversion, has been awarded a contract from the U.S. Navy to develop a carbon monoxide mitigation technique for oxygen systems aboard naval aircraft.

The current oxygen concentration system on naval aircraft is incapable of completely removing carbon monoxide from the pilot’s breathing oxygen. Carbon monoxide in the breathing oxygen can result in the pilot’s becoming drowsy, having blurred vision, or even becoming unconscious. Mainstream is developing a catalytic oxidation reactor to convert the poisonous concentration of carbon monoxide into a safe concentration of carbon dioxide. Mainstream will pursue two different approaches: (1) integrating the oxidizing catalyst into an existing component of the oxygen concentration system; and (2) designing a stand-alone catalytic reactor that can be placed in-line with the existing oxygen concentration system. Both approaches will result in complete oxidation of the carbon monoxide in the pilot’s oxygen feed and will provide the Navy with multiple solutions that can be implemented on a variety of aircraft.

ROCKLEDGE, FL – May 14, 2009 – Mainstream Engineering Corporation, a leading research and development company specializing in advanced thermal control and energy conversion, has been awarded a contract from the U.S. Navy to develop an active submersible thermal protection system for hot/cold water environments

Current submersible thermal protection technology is not capable of meeting the requirements of very cold water or hot water operations in a Shallow Water Combat Submersible. Thermal protection equipment for divers in these situations will be expected to operate for durations in excess of 8 hours in temperatures below 37°F as well as temperatures above 90°F while not tethering the diver to remotely mounted systems. Mainstream has proposed an active thermal protection system that can easily be changed between a heating device and a cooling device without reconfiguring the system. The proposed system will be diver-mounted and will have minimal volume, weight, and power draw characteristics.

Mainstream’s proposed active thermal protection system is an enabling technology for the operation of Shallow Water Combat Submersibles in very cold or very warm water and will extend the capabilities of Seal missions in open water. Beyond the significance of the development of an integrated system for this application, this effort will bring forth several products for both military and commercial markets. Several components from this system can be sold individually for applications such as land- and air-based microclimate systems as well as compartmental heating and cooling systems.

ROCKLEDGE, FL – April 30, 2009 – Mainstream Engineering Corporation (MEC), a leading research and development company specializing in advanced thermal control and energy conversion, has been awarded a Phase II SBIR contract from the U.S. Army Communications-Electronics Command to develop oxygen-enriched combustion systems for diesel electric generators.

Reducing battlefield fuel demand will improve the U.S. armed force’s operational capability and contribute to mission success. During wartime, mobile generators consume the majority of the fuel used by the Army, so increasing generator fuel efficiency will greatly decrease the overall battlefield fuel requirement. Oxygen-enriched diesel combustion can improve fuel-conversion efficiency and power density in these generators while also enabling the use of lower-quality fuels. In Phase I, MEC demonstrated significant improvements in engine performance and showed that air separation membrane modules, which generate the required oxygen-enriched air, can be compact. These membrane modules also produce nitrogen-enriched air as a byproduct, which can be used to control NOX emissions at part load conditions and thereby assure regulatory compliance. The Phase I results also showed that maximizing the benefits of oxygen enrichment requires careful component integration and engine control. In Phase II, MEC will design, build, and demonstrate a variable-air-composition combustion (VACC) system including the membrane module, compressor, valve system, sensors, controller, and electronic fuel injection.