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At least 199 records · Page 11

Boiler materials for ultra supercritical coal power plants

The U.S. Department of Energy (DOE) and the Ohio Coal Development Office (OCDO) have undertaken a project aimed at identifying, evaluating, and qualifying the materials needed for the construction of the critical components of coal-fired boilers capable of operating at much higher efficiencies than current generation of supercritical plants. This increased efficiency is expected to be achieved principally through the use of advanced ultrasupercritical (A-USC) steam conditions up to 760°C (1400°F) and 35 MPa (5000 psi). A limiting factor to achieving these higher temperatures and pressures for future A-USC plants are the materials of construction. The goal of this project is to assess/develop materials technology to build and operate an A-USC boiler capable of delivering steam with conditions up to 760°C (1400°F)/35 MPa (5000 psi). The project has successfully met this goal through a focused long-term public-private consortium partnership. The project was based on an R&D plan developed by the Electric Power Research Institute (EPRI) and an industry consortium that supplemented the recommendations of several DOE workshops on the subject of advanced materials. In view of the variety of skills and expertise required for the successful completion of the proposed work, a consortium led by the Energy Industries of Ohio (EIO) with cost-sharing participation of all the major domestic boiler manufacturers, ALSTOM Power (Alstom), Babcock and Wilcox Power Generation Group, Inc. (B&W), Foster Wheeler (FW), and Riley Power, Inc. (Riley), technical management by EPRI and research conducted by Oak Ridge National Laboratory (ORNL) has been developed. The project has clearly identified and tested materials that can withstand 760°C (1400°F) steam conditions and can also make a 700°C (1300°F) plant more economically attractive. In this project, the maximum temperature capabilities of these and other available high-temperature alloys have been assessed to provide a basis for materials selection and application under a range of conditions prevailing in the boiler. A major effort involving eight tasks was completed in Phase 1. In a subsequent Phase 2 extension, the earlier defined tasks were extended to finish and enhance the Phase 1 activities. This extension included efforts in improved weld/weldment performance, development of longer-term material property databases, additional field (in-plant) corrosion testing, improved understanding of long-term oxidation kinetics and exfoliation, cyclic operation, and fabrication methods for waterwalls. In addition, preliminary work was undertaken to model an oxyfuel boiler to define local environments expected to occur and to study corrosion behavior of alloys under these conditions. This final technical report provides a comprehensive summary of all the work undertaken by the consortium and the research findings from all eight (8) technical tasks including A-USC boiler design and economics (Task 1), long-term materials properties (Task 2), steam- side oxidation (Task 3), Fireside Corrosion (Task 4), Welding (Task 5), Fabricability (Task 6), Coatings (Task 7), and Design Data and Rules (Task 8).

01 COAL, LIGNITE, AND PEAT↗

Design and evaluation of fluidized bed heat recovery for diesel engine systems

The potential of utilizing fluidized bed heat exchangers in place of conventional counter-flow heat exchangers for heat recovery from adiabatic diesel engine exhaust gas streams was studied. Fluidized bed heat recovery systems were evaluated in three different heavy duty transport applications: (1) heavy duty diesel truck; (2) diesel locomotives; and (3) diesel marine pushboat. The three applications are characterized by differences in overall power output and annual utilization. For each application, the exhaust gas source is a turbocharged-adiabatic diesel core. Representative subposed exhaust gas heat utilization power cycles were selected for conceptual design efforts including design layouts and performance estimates for the fluidized bed heat recovery heat exchangers. The selected power cycles were: organic rankine with RC-1 working fluid, turbocompound power turbine with steam injection, and stirling engine. Fuel economy improvement predictions are used in conjunction with capital cost estimates and fuel price data to determine payback times for the various cases.

Hamm, J. R.↗

Synchrotron Characterization of the Oxidation of Advanced Steel Cladding Alloys

Advanced steel alloys are proposed as nuclear fuel claddings due to their high corrosion resistance under extreme conditions of pressure and temperature. APMT is an iron based alloy (Fe-22wt.%Cr-5.8wt.%Al) and Alloy 33 is a mixture of iron, chromium, and nickel (32wt.%Fe-33wt.%Cr-31wt.%Ni). This paper focuses on studying the corrosion mechanisms for these alloys under exposure to superheated steam at 800 deg. C and 1000 deg. C using the synchrotron based X-ray diffraction (XRD) and Hard X-ray photoelectron spectroscopy (HAXPES) techniques. HAXPES data was collected using 4 keV X-rays with a 1x1 mm spot size at X24A beamline. Specimens were mounted on the sample holder. The specimens were tilted 5 degrees relative to the beam and the estimated probe depth (for this fixed energy) is 63 A. The X-ray wavelength for XRD studies at X14A beamline is 0.7792 A with a beam size of of 2 x 0.2 mm{sup 2}. Specimens were exposed to steam environment at 800 and 1000 deg. C for 8, 24, and 48 hours. For Alloy 33; a layer of mixed Cr{sub 2}O{sub 3} and FeCr{sub 2}O{sub 4} oxides is formed after exposure to steam. Specimen tilting indicated that Cr{sub 2}O{sub 3} is formed near the metal/oxide interface and FeCr{sub 2}O{sub 4} was formed on the oxide surface. The oxide peak intensities increased with an increase in steam temperature. The specimen oxidized at 1000 deg. C had well-developed oxide peaks compared to the specimen oxidized at 800 deg. C. For APMT; a layer of mixed α-Al{sub 2}O{sub 3} and monoclinic θ-Al{sub 2}O{sub 3} oxides is formed on the outer surface. The peak intensities of the monoclinic θ-Al{sub 2}O{sub 3} phase, decreases relative to the peaks from the Al{sub 2}O{sub 3} phase with increasing tilt angle. This indicates that the surface is dominated by the θ-Al{sub 2}O{sub 3}. After exposure to steam at 800 deg. C, oxidation of Alloy 33 results in the formation of Cr{sub 2}O{sub 3} oxide with time and absence of both metallic and substoichiometric phases is observed. No nickel peaks are seen on the surface after oxidation at 800 deg. C, however Fe(II) peak is noticed after 8 and 24 hours of steam exposure, which then disappears after 48 hours. This presence of FeCr{sub 2}O{sub 4} oxide phase is observed after 8 and 24 hours. After exposure to steam at 1000 deg. C, the Cr{sub 2}p{sub 3/2} doublet persists at all exposure times, indicating the presence of the FeCr{sub 2}O{sub 4} oxide. Nickel peak is found on the surface at all exposure times and is attributed to the presence of Ni(OH){sub 2} phase. This may be due to increased diffusion of Ni through chromic oxide scale at higher temperature as compared to 800 deg. C. This nickel reacts with steam at 1000 deg. C to form Ni hydroxide at the surface. For APMT, after exposure to steam at 800 and 1000 deg. C, no Al and Cr metal peaks are seen. Growth of oxide layer is seen with increase in exposure time. The oxide structure contains mainly Al{sub 2}O{sub 3} oxide with the addition of mixed oxide (Al{sub x}Cr{sub 1-x}){sub 2}O{sub 3}. These results demonstrate that Cr diffuses into the alumina layer. (authors)

36 MATERIALS SCIENCE↗

Operating capability and current status of the reactivated NASA Lewis Research Center Hypersonic Tunnel Facility

The NASA Lewis Research Center's Hypersonic Tunnel Facility (HTF) is a free-jet, blowdown propulsion test facility that can simulate up to Mach-7 flight conditions with true air composition. Mach-5, -6, and -7 nozzles, each with a 42 inch exit diameter, are available. Previously obtained calibration data indicate that the test flow uniformity of the HTF is good. The facility, without modifications, can accommodate models approximately 10 feet long. The test gas is heated using a graphite core induction heater that generates a nonvitiated flow. The combination of clean-air, large-scale, and Mach-7 capabilities is unique to the HTF and enables an accurate propulsion performance determination. The reactivation of the HTF, in progress since 1990, includes refurbishing the graphite heater, the steam generation plant, the gaseous oxygen system, and all control systems. All systems were checked out and recertified, and environmental systems were upgraded to meet current standards. The data systems were also upgraded to current standards and a communication link with NASA-wide computers was added. In May 1994, the reactivation was complete, and an integrated systems test was conducted to verify facility operability. This paper describes the reactivation, the facility status, the operating capabilities, and specific applications of the HTF.

Thomas, Scott R.↗

Operating capability and current status of the reactivated NASA Lewis Research Center hypersonic tunnel facility

The NASA Lewis Research Center's Hypersonic Tunnel Facility (HTF) is a free-jet, blowdown propulsion test facility that can simulate up to Mach-7 flight conditions with true air composition. Mach-5, -6, and -7 nozzles, each with a 42-in. exit diameter, are available. Previously obtained calibration data indicate that the test flow uniformity of the HTF is good. The facility, without modifications, can accomodate models approximately 10 ft long. The test gas is heated using a graphite core induction heater that generates a nonvitiated flow. The combination of clean-air, large-scale, and Mach-7 capabilities is unique to the HTF and enables an accurate propulsion performance determination. The reactivation of the HTF, in progress since 1990, includes refurbishing the graphite heater, the steam generation plant, the gaseous oxygen system, and all control systems. All systems were checked out and recertified, and environmental systems were upgraded to meet current standards. The data systems were also upgraded to current standards and a communication link with NASA-wide computers was added. In May 1994, the reactivation was complete, and an integrated systems test was conducted to verify facility operability. This paper describes the reactivation activities, the facility status, the operating capabilities, and specific applications of the HTF.

Thomas, S.↗

Uncertainty Propagation from Experiment Measurements to Modeling Approaches: A Case for SMR Steam Entrainment Testing

To license new and advanced reactor designs, regulators must be convinced that their unique safety cases—relative to existing large scale reactors—have been adequately addressed by the designed reactor protection systems. In water cooled small modular reactors (SMRs), droplet entrainment in steam flow has significant implications on the progression of accident scenarios due to its compact design features, which requires representative test data applicable to SMR designs. Computer code, modeling and simulation (M&S) tools and models require adequate verification, assessment, and qualification. This includes M&S results validation against scaled empirical data within allowable uncertainty bands to gain regulatory approvals during the various stages of reactor system design, demonstration, and commercialization. However, measurement uncertainty within the empirical datasets and test data applicability ranges requires careful consideration of M&S inputs (i.e., boundary conditions, and initial conditions), and verification and validation efforts. This study focuses on uncertainty quantification in designing scaled test facilities for SMR applications with appropriate measurements and a standard data-reduction method to estimate thermal hydraulics characteristics parameters that incorporate physics phenomena of interest. In addition, this study supports the evaluation model development and assessment process using M&S that interfaces with advanced computing tools and digital twin capabilities. This will allow synchronization between experiment and modeling approaches for droplet entrainment testing and analysis, improving diagnostics, prognostics, and decision-making to accelerate regulatory approval.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Skin friction reduction in supersonic flow by injection through slots, porous sections and combinations of the two

An experimental study of skin friction reduction in a Mach 3.0 air steam with gaseous injection through a tangential slot, a porous wall section, and combinations of the two was conducted. The primary data obtained were wall shear values measured directly with a floating element balance and also inferred from Preston Tube measurements. Detailed profiles at several axial stations, wall pressure distributions and schlieren photographs are presented. The data indicate that a slot provides the greatest skin friction reduction in comparison with a reference flat plate experiment. The porous wall section arrangement suffers from an apparent roughness-induced rise in skin friction at low injection rates compared to the flat plate. The combination schemes demonstrated a potential for gain.

Schetz, J. A.↗

Smart Manufacturing Technologies and Data Analytics for Improving Energy Efficiency in Industrial Energy Systems

Smart manufacturing and advanced data analytics can help the manufacturing sector unlock energy efficiency from the equipment level to the entire manufacturing facility and the whole supply chain. These technologies can make manufacturing industries more competitive, with intelligent communication systems, real-time energy savings, and increased energy productivity. Smart manufacturing can give all employees in an organization the actionable information they need, when they need it, so that each person can contribute to the optimal operation of the corporation through informed, data-driven decision making. This paper examines smart technologies and data analytics approaches for improving energy efficiency and reducing energy costs in process-supporting energy systems. It dives into energy-saving improvement opportunities through smart manufacturing technologies and sophisticated data collection and analysis. The energy systems covered in this paper include those with motors and drives, fans, pumps, air compressors, steam, and process heating.

Nimbalkar, Sachin U.↗

WISE-CASING: Time Domain Reflectometry Data from Cymric Field, CA

The objective of this field test is to validate several technologies for non-invasive well integrity assessment using existing wells with a known completion. The tests were made at the Cymric oil field, which is a steam flood operation. The wells therefore undergo similar downhole conditions as geothermal wells. The Cymric field is mainly a cyclic steam operation where wells are 1000-15-00 ft in depth and the reservoir occupies the bottom 400ft. The maximum temperatures can exceed 500 degrees F and the well spacing is very close, often less than 50m. The field plan consisted of applying the Time Domain Reflectometry (TDR) method to the wells. The input voltages were set as 70 V shows the TDR responses at frequencies of 450 kHz, 2500 kHz, and 4500 kHz. There is a summary report will full information about the field tests.

15 GEOTHERMAL ENERGY↗

Data-driven Quasi-static Surrogate Model for Nuclear-powered Integrated Energy Systems

The integration of nuclear power into energy systems presents a promising avenue to address the growing global energy demands while minimizing greenhouse gas emissions. In this paper, we introduce a data-driven quasi-static surrogate model for nuclear-powered Integrated Energy Systems (IES) that comprises various components, including a small modular reactor (SMR), energy manifold (EM), balance of plant (BOP), high-temperature steam electrolysis (HTSE), and district heating (DH) system. Traditional physics-based models for these components often entail significant computational overhead and time consumption, necessitating the development of efficient surrogate models. The development of a complete surrogate model for the IES involves the creation of individual surrogate models for each component, leveraging machine learning techniques and simulated data. These isolated surrogate models are subsequently integrated, enabling a holistic view of the IES and reducing the computational burden associated with detailed physics-based simulations. This paper outlines the development process, validation, and the performance evaluation of the surrogate models. The findings shed light on the accuracy and applicability of the surrogate models in practical scenarios, demonstrating their potential to expedite the analysis of nuclear-powered IES and inform future research and development efforts.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Systematic Structure–Property Relationship Studies in Palladium-Catalyzed Methane Complete Combustion

To limit further rising levels in methane emissions from stationary and mobile sources and to enable promising technologies based on methane, the development of efficient combustion catalysts that completely oxidize CH 4 to CO 2 and H 2 O at low temperatures in the presence of high steam concentrations is required. Palladium is widely considered as one of the most promising materials for this reaction, and a better understanding of the factors affecting its activity and stability is crucial to design even more improved catalysts that efficiently utilize this precious metal. Here we report a study of the effect of three important variables (particle size, support, and reaction conditions including water) on the activity of supported Pd catalysts. We use uniform palladium nanocrystals as catalyst precursors to prepare a library of well-defined catalysts to systematically describe structure–property relationships with help from theory and in situ X-ray absorption spectroscopy. With this approach, we confirm that PdO is the most active phase and that small differences in reaction rates as a function of size are likely due to variations in the surface crystal structure. We further demonstrate that the support exerts a limited influence on the PdO activity, with inert (SiO 2 ), acidic (Al 2 O 3 ), and redox-active (Ce 0.8 Zr 0.2 O 2 ) supports providing similar rates, while basic (MgO) supports show remarkably lower activity. Finally, we show that the introduction of steam leads to a considerable decrease in rates that is due to coverage effects, rather than structural and/or phase changes. Altogether, the data suggest that to further increase the activity and stability of Pd-based catalysts for methane combustion, increasing the surface area of supported PdO phases while avoiding strong adsorption of water on the catalytic surfaces is required. Furthermore, this study clarifies contrasting reports in the literature about the active phase and stability of Pd-based materials for methane combustion.

36 MATERIALS SCIENCE↗

Criticality calculation package and its use for a spent fuel storage pool with steam layer - 14324

Criticality studies need several calculations with small variations in a number of parameters. Therefore, a calculation package written at VTT in order to facilitate sensitivity studies in criticality calculations was used. This package is based on MCNP5 [1], and consists of a data transfer and analysis program written in Perl, and a set of pseudo inputs for the transport and storage systems including the fuel assembly. The pseudo inputs contain key words that are replaced by a given value for the specific parameter. In this paper, the package is described in more detail including the new modifications needed for this study. The usability will be demonstrated with a study of the fuel pool in the case of steam gathered under the support plates of the pool. In the new pool model the steam layer was added as a water layer with a very low density. The density of this layer, i.e. the steam density, could be varied as well as the thickness of the layer. This package was then used to study the reactivity effect of the moderator density, the steam density and the thickness of the steam layer. As can be expected the strongest effect was obtained with the moderator density. However, the steam density seemed not to affect the reactivity while the thickness of the layer had a small effect. (author)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Dynamic Modeling, Parameter Estimation, and Data Reconciliation of a Supercritical Pulverized Coal-Fired Boiler

A high-fidelity, spatially distributed dynamic model of a supercritical pulverized coal-fired boiler was developed for calculating transient thermal profiles of the boiler tubes, which are often not measured or unmeasurable in industrial settings due to the harsh operating conditions. In this work, rigorous models of the subcritical and supercritical steam properties, which can be highly nonlinear, were used to capture the transition between two-phase and one-phase flow, respectively, as supercritical boilers frequently transition through the critical point during load-following operation. The transient boiler model was also used for data reconciliation and parameter estimation for the purpose of model validation against industrial data. An approach was developed to reduce the size of large-scale reconciliation problem by focusing on the implementation of bias terms for the reconciled variables, which can be estimated in place of the reconciled variables themselves. In addition, a functional approximation of the reconciliation problem was defined so that it can be more simply optimized. Combining this functional approximation optimization with reformulation of the reconciliation problem considering measurement biases can significantly improve the tractability of many such large-scale problems. The validated boiler model was then used to study transient responses under load-following operation with specific attention on the calculation of unmeasurable variables.

42 ENGINEERING↗

Understanding Environmental Barrier Coating Lifetimes and Performance for Industrial Gas Turbines

Hydrogen or hydrogen blend fuels are expected to replace natural gas in land-based industrial gas turbines (IGTs) to support a greener power economy. Silicon carbide (SiC) base ceramic matrix composites (CMCs) are considered for replacement of Ni-based superalloys to facilitate future efficiency improvements. SiC CMCs require environmental barrier coatings (EBCs) to mitigate volatilization from high-temperature steam, thus making the EBC lifetime critical information for identifying CMC component lifetimes. Here, the goal of this project is to determine the maximum bond coating temperature underneath the EBC for achieving an IGT component lifetime goal of 25,000 h, which is far greater than current CMC component lifetime requirements for aeroturbine applications. To provide data for the lifetime model, laboratory testing used atmospheric plasma-sprayed rare-earth silicate EBCs on monolithic SiC substrates with an intermediate Si bond coating. Specimens exposed to 1-h thermal cycles in flowing air–steam environments and reaction kinetics were assessed from 700 °C to 1350 °C by measuring the thickness of the thermally grown silica scales. The silica growth and phase transformation appear critical in predicting EBC lifetime and several strategies have been explored to reduce the oxide growth rate and improve EBC durability at elevated temperatures. Advanced characterization using Raman spectroscopy has helped clarify this system.

08 HYDROGEN↗

Strength and rupture geometry of un-irradiated C26M FeCrAl under LOCA burst testing conditions

Ferritic iron-chromium-aluminum (FeCrAl) alloys are an accident tolerant fuel candidate to replace the incumbent Zr-based claddings. Nuclear grade FeCrAl alloys are marked by superior high temperature mechanical behavior and exceptional steam oxidation resistance, both of which increase safety margins during accident scenarios. In the present study, the loss of coolant accident (LOCA) burst behaviors of three un-irradiated commercially fabricated cladding materials in a simulated LOCA environment were compared: (1) T35Y2, a 1 st generation nuclear grade FeCrAl, (2) C26M, a 2 nd generation nuclear grade FeCrAl, and (3) Zircaloy-2. Both FeCrAl alloys showed improved mechanical strength and steam oxidation resistance compared to Zircaloy-2. C26M claddings burst at significantly higher temperatures for all tested engineering hoop stresses, had limited ballooning, and demonstrated preferential fuel retention behavior in terms of burst opening area and length. High temperature tensile data for C26M is also presented. For both un-irradiated FeCrAl alloys, it was found that a distinct “threshold” burst stress signified the transition between small and large openings. Finally, higher threshold hoop stresses were associated with higher uniaxial strength for the FeCrAl alloys, indicating that tensile data, rather than creep data, could be useful for predicting rupture size and assessing fuel dispersal concerns.

36 MATERIALS SCIENCE↗

Steam chugging analysis in single-vent vapor injection

A complete cycle of the periodic steam chugging phenomenon is analyed. Steam velocity and pressure variations in the vent are described by one-dimensional conservation equations. This is coupled either to the water slug model when water is in the vent, or, the infinite pool spherical bubble model at the vent exit during bubble growth. An isolated spherical bubble model is used for computing the collapse pressures. Comparisons of the model predictions with the UCLA 1/12-scale and the Japan 1/6-scale data indicate that the vent-pipe model predicts the vent-clearing times and the bubble growth times well. In addition, the predicted maximum chugging heights compared well with those measured in the Japan data. On bubble collapse pressures, the comparison with the spherical bubble model predictions is only fair. The model generally overpredicts the magnitude of the spikes. On examining the effects of pool subcooling and steam mass flux, general agreement is found between the predicted trends and those measured.

Lee, C. K. B.↗

Understanding EBC Lifetimes and Performance for Industrial Gas Turbines

Hydrogen or hydrogen blend fuels are expected to replace natural gas in land-based industrial gas turbines (IGTs) to support a greener power economy. Silicon carbide (SiC) base ceramic matrix composites (CMCs) are considered for replacement of Ni-based superalloys to facilitate future efficiency improvements. SiC CMCs require environmental barrier coatings (EBCs) to mitigate volatilization from high-temperature steam, thus making the EBC lifetime critical information for identifying CMC component lifetimes. The goal of this project is to determine the maximum bond coating temperature underneath the EBC for achieving an IGT component lifetime goal of 25,000 h, which is far greater than current CMC component lifetime requirements for aero-turbine applications. To provide data for the lifetime model, laboratory testing used plasma-sprayed rare-earth silicate EBCs on monolithic SiC substrates with an intermediate Si bond coating. Specimens exposed to 1-h thermal cycles in flowing air-steam environments and reaction kinetics were assessed from 700°-1350°C by measuring the thickness of the thermally grown silica scales. The silica growth and phase transformation appear critical in predicting EBC lifetime and several strategies have been explored to reduce the oxide growth rate and improve EBC durability at elevated temperatures. Advanced characterization using Raman spectroscopy has helped clarify this system.

Ridley, Mackenzie↗

Highly Available Nuclear Power for Mission-Critical Applications

Some energy consumers require power on an anytime, all-year-round basis with a high level of certainty, including defense installations, isolated communities, and some industrial processes. For these customers, interruptions in electricity or heat can mean substantial financial loss or even loss of life. In the absence of grid-scale energy storage, a high level of power availability can be accomplished only through the robustness and redundancy of power generators. The NuScale small modular reactor design is well suited to provide highly available power because of several features related to both the nuclear steam supply system and the overall plant design. In analogy to Redundant Array of Independent Disks (RAID) systems used to provide highly reliable data storage, a NuScale plant can assure sustained power generation by virtue of its Redundant Array of Integral Reactors (RAIR).This paper describes the NuScale RAIR plant features and summarizes the results of a rigorous analysis of RAIR availability as a function of power or, conversely, the RAIR plant output power as a function of power availability. The analysis utilized the Matrix Laboratory code (MATLAB) and included probability distributions for the frequency and duration of module outages due to planned and unplanned events. Further, the study evaluated the impact of implementing turbine bypass rather than module shutdown and using one or more modules to supply house loads in the case of loss of off-site power (LOOP). Availability results are presented for a 12-module RAIR plant with and without turbine bypass enabled during a LOOP and for different possible connections to the off-site power distribution grid and dedicated service loads. Results indicate that a very high level of availability can be achieved at relatively high power output levels, regardless of turbine bypass and dedicated load connection, compared to the operating fleet.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗