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All sourcesNASA NTRSDOE OSTI
NASA NTRS2002

Stirling Research Laboratory Providing Independent Performance Verification of Convertors for a Stirling Radioisotope Generator

The Department of Energy (DOE), Germantown, Maryland, Stirling Technology Company (STC), Kennewick, Washington, and NASA Glenn Research Center are developing a free-piston Stirling convertor for a high-efficiency Stirling Radioisotope Generator for NASA Space Science missions. This generator is being developed for multimission use, including providing electric power for unmanned Mars rovers and for deep space missions. STC is developing the 55-W Technology Demonstration Convertor (TDC) under contract to DOE. Glenn is conducting an in-house technology project to assist in developing the convertor for readiness for space qualification and mission implementation. As part of this effort, a Stirling Research Laboratory was established to test the TDC's and related technologies. A key task is providing an independent verification and validation of the TDC performance. Four TDC's are now being tested at Glenn. Acceptance testing has been completed for all convertors, and in general, performance agreed well with that achieved by STC prior to the delivery of the convertors. Performance mapping has also been completed on two of the convertors over a range of hot-end temperatures (450 to 650 C), cold-end temperatures (80 to 120 C), and piston amplitudes (5.2 to 6.2 mm). These test data are available online at http://www.grc.nasa.gov/WWW/tmsb/. The TDC's can be tested in either a horizontal orientation with dual-opposed convertors or in a vertical orientation with a single convertor. Synchronized dual-opposed pairs are used for dynamically balanced operation that results in very low levels of vibration. The Stirling Research Laboratory also supports launch environment testing of the TDC's in Glenn's Structural Dynamics Laboratory and electromagnetic interference and electromagnetic compatibility characterization and reduction efforts. In addition, the TDC's will be used for long-term endurance testing, and preparations are underway for unattended operation.

Thieme, Lanny G.↗
DOE OSTI2021

Stable perovskite-fluorite dual-phase composites synthesized by one-pot solid-state reactive sintering for protonic ceramic fuel cells

We report that this work synthesized a series of oxide composites with nominal compositions of BaCe 05 Zr 0.4 Y 0.1 O 3-δ (BCZY)-Ce 0.5 Y 0.5 O 2-δ (YDC) based on the BCZY/YDC molar ratios of 0.5:1, 1:1, 2:1, and 4:1 (BCZY-YDC-0.5–1, BCZY-YDC-1-1, BCZY-YDC-2-1, and BCZY-YDC-4-1) using a one-pot solid state reactive sintering (SSRS) method. The X-ray diffraction (XRD) patterns and refinement proved that the one-pot SSRS at 1450 °C for 12 h could achieve the perovskite-fluorite dual-phase composites (DPCs) with the desired structure compositions. The scanning electron microscopy (SEM) images showed that the two DPCs of BCZY-YDC-1-1 and BCZY-YDC-2-1 formed excellent percolation for perovskite and fluorite phases. The conductivity measurement by electrochemical impedance spectroscopy (EIS) and the transference number measurement by the electromotive force (EMF) test proved that changing the BCZY/YDC molar ratio and operating condition could adjust the DPC's conduction property to make them suitable for electrolytes and electrode scaffolds for protonic ceramic fuel cells (PCFCs). The long-term conductivity testing and the crystal structure analysis after EMF testing under versatile conditions indicated that the DPCs of BCZY-YDC-2-1 and BCZY-YDC-1-1 were durable PCFC component materials. The PCFC button cells with the as-discovered BCZY-YDC-2-1 and BCZY-YDC-1-1 as an electrolyte and an anode scaffold, respectively, and the reported Ba–Ce–Fe–Co–O perovskite-perovskite composite as a cathode showed promising performance under H 2 /air gradient.

08 HYDROGEN↗
DOE OSTI2022

Ru-promoted perovskites as effective redox catalysts for CO2 splitting and methane partial oxidation in a cyclic redox scheme

The current study reports AxA’1-xByB’1-yO3- perovskite redox catalysts (RCs) for CO2-splitting and methane partial oxidation (POx) in a cyclic redox scheme. Strontium (Sr) and iron (Fe) were chosen as A and B site elements with A’ being lanthanum (La), samarium (Sm) or yttrium (Y), and B’ being manganese (Mn), or titanium (Ti) to tailor their equilibrium oxygen partial pressures (P_(O_2 ) s) for CO2-splitting and methane partial oxidation. DFT calculations were performed for predictive optimization of the oxide materials whereas experimental investigation confirmed the DFT predicted redox performance. The redox kinetics of the RCs improved significantly by 1 wt.% ruthenium (Ru) impregnation without affecting their redox thermodynamics. Ru impregnated LaFe0.375Mn0.625O3 (A=0, A’=La, B=Mn, and B’=0) was the most promising RC in terms of its superior redox performance (CH4/CO2 conversion >90% and CO selectivity~ 95%) at 800oC. Long-term redox testing over Ru impregnated LaFe0.375Mn0.625O3 indicated stable performance during the first 30 cycles following with a ~25% decrease in the activity during the last 70 cycles. Air treatment was effective to reactivate the redox catalyst. Detailed characterizations revealed the underlying mechanism for redox catalyst deactivation and reactivation. Furthermore, this study not only validated a DFT guided mixed oxide design strategy for CO2 utilization but also provides potentially effective approaches to enhance redox kinetics as well as long-term redox catalyst performance.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Subcomponent Validation of Composite Joints for the Marine Energy Advanced Materials Project

The Marine Energy Advanced Materials project is an ongoing multi-year, multi-lab project with the main goals of addressing barriers and uncertainties facing marine energy developers in adopting advanced materials for structural applications. NREL's goals of the project were to address subcomponents testing needs for marine energy materials, to improve understanding of design allowables at the full-scale and provide near net-scale static and fatigue data of composite subcomponents using materials applicable to the marine energy industry. In the long term, the test method development and data generated would be used to inform standards development. This report outlines perhaps one of the largest-scale studies conducted with regards to saltwater conditioning of various composite material subcomponents and their subsequent structural validation, specifically directed at the marine renewable energy industry. A variety of fiberglass composite panels with epoxy and vinyl ester epoxy resin systems were manufactured at Montana State University, which were then used to manufacture an array of different types of subcomponent test specimens at the National Renewable Energy Laboratory's Flatirons Campus. These subcomponents were in the form of T-bolt and double-ended-insert specimens, which were intended to represent bonded and mechanical bolted connections for thick composite laminates, metal-metal and composite lap shear specimens to evaluate adhesion of constituent materials, and adhesive beam-shear specimens as part of an effort to better evaluate the characteristics of thick adhesive bondlines. Overall, the materials used were fiberglass reinforced epoxy and vinyl ester matrix composites, epoxy and methacrylate adhesives, and 316 and 2507 stainless steels. Specimens were then conditioned in salt water at various temperatures and for various periods of time at Florida Atlantic University and Pacific Northwest National Laboratory. All specimens were then mechanically characterized and validated using various test methods under static and fatigue loading conditions at NREL's Structural Technology Laboratory. Throughout the conditioning and mechanical validation process, valuable experience was gained, which will help guide future test method development for marine energy materials. In many instances, the results indicated similar observations as to what had been observed during previous coupon scale characterization efforts that provided a vital understanding of the scale up process. However in some instances, unexpected phenomena were observed, such as interactions between the adhesives and 316 steel. Furthermore, some materials exhibited significant degradation due to the saltwater conditioning. Ultimately, this report provides a detailed summary of the specimens that were designed, the subcomponent test methods that were developed, and the results that were generated, which will serve as important guidance for marine renewable energy developers and researchers for future structural designs and validation.

16 TIDAL AND WAVE POWER↗
DOE OSTI2021

Evaluating ZEBRA Battery Module under the Peak-Shaving Duty Cycles

With the recent rapid increase in demand for reliable, long-cycle life, and safe battery technologies for large-scale energy-storage applications, a battery module based on ZEBRA battery chemistry is extensively evaluated for its application in peak shaving duty cycles. First, this module is tested with a full capacity cycle consisting of a charging process (factory default) and a discharging process with a current of 40 A. The battery energy efficiency (discharge vs. charge) is about 90%, and the overall energy efficiency is 80.9%, which includes the auxiliary power used to run the battery management system electronics and self-heating to maintain the module operating temperature (265 °C). Generally, because of the increased self-heating during the holding times that exist for the peak shaving duty cycles, the overall module efficiency decreases slightly for the peak-shaving duty cycles (70.7–71.8%) compared to the full-capacity duty cycle. With a 6 h, peak-shaving duty cycle, the overall energy efficiency increases from 71.8% for 7.5 kWh energy utilization to 74.1% for 8.5 kWh. We conducted long-term cycling tests of the module at a 6 h, peak-shaving duty cycle with 7.5 kWh energy utilization, and the module exhibited a capacity degradation rate of 0.0046%/cycle over 150 cycles (>150 days).

25 ENERGY STORAGE↗
DOE OSTI2025

Corrosion and Mechanical Durability Testing in High Temperature Molten Sulfur (CRADA Final Report)

The overall goal of the project is to explore and identify suitable candidate materials for high-temperature molten sulfur thermal energy storage (TES) operating up to a maximum temperature of 400°C–420°C for industrial process heat applications. A detailed corrosion and strength analysis of coupons subjected to long-term thermal testing in molten sulfur will be conducted to characterize the fundamental corrosion mechanism, corrosion rates, and mechanical durability. The results from the project contribute to the engineering design of sulfur TES systems with desired longevity and lower construction and maintenance costs. The research outcome benefits the TES research and development community by providing detailed corrosion and degradation information for more effective engineering design of the molten sulfur TES containment. It improves the diversity and reliability of the renewable technologies available for the U.S. industries and U.S. power grid.

14 SOLAR ENERGY↗
NASA NTRS1985

Long-life high performance fuel cell program

A multihundred kilowatt Regenerative Fuel Cell for use in a space station is envisioned. Three 0.508 sq ft (471.9 cm) active area multicell stacks were assembled and endurance tested. The long term performance stability of the platinum on carbon catalyst configuration suitability of the lightweight graphite electrolyte reservoir plate, the stability of the free standing butyl bonded potassium titanate matrix structure, and the long life potential of a hybrid polysulfone cell edge frame construction were demonstrated. A 18,000 hour demonstration test of multicell stack to a continuous cyclical load profile was conducted. A total of 12,000 cycles was completed, confirming the ability of the alkaline fuel cell to operate to a load profile simulating Regenerative Fuel Cell operation. An orbiter production hydrogen recirculation pump employed in support of the cyclical load profile test completed 13,000 hours of maintenance free operation. Laboratory endurance tests demonstrated the suitability of the butyl bonded potassium matrix, perforated nickel foil electrode substrates, and carbon ribbed substrate anode for use in the alkaline fuel cell. Corrosion testing of materials at 250 F (121.1 C) in 42% wgt. potassium identified ceria, zirconia, strontium titanate, strontium zirconate and lithium cobaltate as candidate matrix materials.

Martin, R. E.↗
NASA NTRS1997

Use of the Aromascan(TM) Instrument for Nonsubjective Evaluation of Rodent Spaceflight Hardware

This report describes the verification and utilization of the AromaScan(TM) (Hollis, NH) instrument for the ground-based evaluation of odor containment by various spaceflight habitats developed at NASA's Ames Research Center (ARC). The AromaScan(TM) instrument is an electronic odor detection system consisting of 32 polymer sensors that respond differentially to 10 different chemical groups present in an air sample. The AromaScan(TM) system also includes neural network software for constructing a database of known odors, against which an unknown odor can be compared. At present, the standard method for characterizing rodent odor containment during the development and testing of spaceflight hardware is the use of a human odor assessment panel. However, this can be a very time consuming and costly process, and the results are inherently subjective. The AromaScan(TM) system should produce more consistent and objective results, as well as a cost savings in the long term. To test and verify the AromaScan(TM) instrument, daily air samples will be collected from the exhaust port of rodent habitats, during experiment development tests, then injected into the instrument and used to create a database of recognizable odors. Human sniff tests will be performed in conjunction with the AromaScan(TM) analysis, and the results will be correlated. We will then teach the neural network to differentiate between an acceptable and an unacceptable odor profile, as defined by the human sniff test, and to be able to accurately identify an odor that would not pass a sniff panel. The results of our efforts will be to verify that the AromaScan(TM) system is a valuable alternative to human sniff panel assessments for the early iterative process of designing and testing rodent waste filters for spaceflight. Acceptance by a human panel will remain one of the final criteria for successful rodent habitat development.

Scribner, K. A.↗
NASA NTRS1971

Development of space stable thermal control coatings for use on large space vehicles

The evaluation and environmental testing of zinc orthotitanate pigments for use as space stable thermal control coatings on large space vehicles are discussed. Electron paramagnetic resonance spectra of the pigments and their precursor compounds are examined. A continuing study of the spectral intensity of mercury-argon and mercury-xenon sources in reported. Results of long term environmental testing of commercially available, strippable, protective coatings are discussed.

Gilligan, J. E.↗
DOE OSTI2020

Sodium Exposure Tests of A709 Steel (FY2020 Progress Report)

Sodium exposure tests were conducted on the first commercial heat, H58776 of A709 steel. Six different processing and heat treatment conditions were investigated, including three processing conditions, namely, Argon-Oxygen-Decarburization (AOD), Electro-slag Remelting (ESR), and Electro-slag Remelting with subsequent homogenization (HOMO), and two heat treatment conditions, i.e. solution annealing at 1100°C (SA1100°C) or 1150°C (SA1150°C). Specimens of AOD-SA1100°C, AOD-SA1150°C, ESR-SA1100°C, ESR-SA1150°C, HOMO-SA1100°C, and HOMO-SA1150°C were tested in sodium at 650°C and for times up to 10,152 h. Specimens in the AOD-SA1100°C and AOD-SA1150°C conditions were also tested in sodium at 550 and 600°C. Parallel thermal aging experiments were carried out for comparison with sodium exposure tests to separate the thermal and sodium effects. It was found that A709 H58776 generally showed a weight loss after sodium exposures at 650°C except a few data points of the ESR-SA1100°C specimens. The corrosion rate showed large variations in the initial stage and decreased with increasing exposure time. Long-term exposure tests are needed to determine its steady-state corrosion rate. The AOD-SA1100°C and HOMO-SA1100°C specimens showed similar tensile responses after thermal or sodium exposures at 650°C. The yield stress increased, the ultimate tensile strength decreased, and the uniform and total elongations were reduced after thermal or sodium exposures. A longer exposure time had a minimal effect on the tensile strength but further reduced the tensile ductility. The sodium-exposed specimens had higher tensile strength than the thermally-aged specimens. In contrast, the ESR-SA1100°C specimens showed an increase in the yield stress and the ultimate tensile strength after thermal or sodium exposures at 650°C and ~10,000 h. The AOD-SA1150°C and ESR-SA1150°C specimens showed similar tensile behavior after thermal or sodium exposures at 650°C.Thermal or sodium exposures at 650°C increased the yield stress, decreased the ultimate tensile strength, and reduced uniform and total elongations. There were minimal differences in tensile properties between the sodium-exposed and thermally-aged specimens after an ~3000 h exposure. After an exposure for ~10,000 h the sodium-exposed specimens showed higher yield stress and ultimate tensile strength and lower uniform and total elongations than the thermally-aged specimens. For the HOMO-SA1150°C specimens, thermal or sodium exposures at 650°C significantly increased the yield stress but had a minimal effect on the ultimate tensile strength. Both uniform and total elongations were significantly reduced at an exposure time of ~3,000 h, and they were further reduced after an exposure of ~10,000 h. The sodium-exposed specimens had lower tensile ductility than the thermally-aged specimens. Before exposure, the stress-strain curves of the specimens in all six processing-heat treatment conditions showed serrations indicating the dynamic aging effect at 650°C. Thermal aging or sodium exposures at 650°C after ~10,000 h completely removed the serrations of the flow curves in A709 H58776, indicating strong precipitation during thermal or sodium exposures. Longer-term sodium exposure tests are needed to determine the steady-state corrosion rates in sodium for A709 H58776 and fully understand the influence of sodium exposures on its mechanical performance.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Assessing the Oxidative Stability of Anion Exchange Membranes in Oxygen Saturated Aqueous Alkaline Solutions

While anion exchange membrane water electrolyzers show promise as a source of green hydrogen using low-temperatures and non-platinum group metal catalysts, many concerns must be addressed. A primary challenge for the development of high-performance anion exchange membrane water electrolyzers is the fabrication of a stable membrane that will be able to survive long-term stability test while maintaining high anion conductivity, which is a necessity for a durable water electrolyzer. This method will present a standardized protocol that can be used by researchers to assess the quality of their AEM materials and be able to provide insight into how materials may be degrading and how to improve the quality of AEMs. Using Mohr or Volhard titration to measure ion-exchange capacity, EIS to determine the ionic conductivity, NMR and FTIR to understand the extent of membrane degradation over time, and mechanical analyzers to determine the strength of their AEMs, this standardized protocol will guide researchers to determining and improving upon the long-term durability and performance of their AEM materials.

36 MATERIALS SCIENCE↗
NASA NTRS2016

Degradation of Leakage Currents and Reliability Prediction for Tantalum Capacitors

Two types of failures in solid tantalum capacitors, catastrophic and parametric, and their mechanisms are described. Analysis of voltage and temperature reliability acceleration factors reported in literature shows a wide spread of results and requires more investigation. In this work, leakage currents in two types of chip tantalum capacitors were monitored during highly accelerated life testing (HALT) at different temperatures and voltages. Distributions of degradation rates were approximated using a general log-linear Weibull model and yielded voltage acceleration constants B = 9.8 +/- 0.5 and 5.5. The activation energies were Ea = 1.65 eV and 1.42 eV. The model allows for conservative estimations of times to failure and was validated by long-term life test data. Parametric degradation and failures are reversible and can be annealed at high temperatures. The process is attributed to migration of charged oxygen vacancies that reduce the barrier height at the MnO2/Ta2O5 interface and increase injection of electrons from the MnO2 cathode. Analysis showed that the activation energy of the vacancies' migration is ~ 1.1 eV.

acceleration factors↗
NASA NTRS2004

Reliability Quantification of the Flexure: A Critical Stirling Convertor Component

Uncertainties in the manufacturing, fabrication process, material behavior, loads, and boundary conditions results in the variation of the stresses and strains induced in the flexures and its fatigue life. Past experience and the test data at material coupon levels revealed a significant amount of scatter of the fatigue life. Owing to these facts, the design of the flexure, using conventional approaches based on safety factor or traditional reliability based on similar equipment considerations does not provide a direct measure of reliability. Additionally, it may not be feasible to run actual long term fatigue tests due to cost and time constraints. Therefore it is difficult to ascertain material fatigue strength limit. The objective of the paper is to present a methodology and quantified results of numerical simulation for the reliability of flexures used in the Stirling convertor for their structural performance. The proposed approach is based on application of finite element analysis method in combination with the random fatigue limit model, which includes uncertainties in material fatigue life. Additionally, sensitivity of fatigue life reliability to the design variables is quantified and its use to develop guidelines to improve design, manufacturing, quality control and inspection design process is described.

Shah, Ashwin R.↗
NASA NTRS2002

Facility and Methods Developed for Simulated Space Vacuum Ultraviolet Exposure Testing of Polymer Films

Vacuum ultraviolet (VUV) radiation of wavelengths between 115 and 200 nm produced by the Sun in the space environment can degrade polymer films, producing changes in their optical, mechanical, and chemical properties. These effects are particularly important for thin polymer films being considered for ultralightweight space structures, because, for most polymers, VUV radiation is absorbed in a thin surface layer. The NASA Glenn Research Center has developed facilities and methods for long-term ground testing of polymer films to evaluate space environmental VUV radiation effects. VUV exposure can also be used as part of combined or sequential simulated space environmental exposures to determine combined damaging effects with other aspects of the space environment, which include solar ultraviolet radiation, solar flare x-rays, electron and proton radiation, atomic oxygen (for low-Earth-orbit missions), and temperature effects. Because the wavelength sensitivity of VUV damage is not well known for most materials, Glenn's VUV facility uses a broad-spectrum deuterium lamp with a magnesium fluoride window that provides output between 115 and 200 nm. Deuterium lamps of this type were characterized by the National Institute of Standards and Technology and through measurements at Glenn. Spectral irradiance measurements show that from approximately 115 to 160 nm, deuterium lamp irradiance can be many times that of air mass zero solar irradiance, and as wavelength increases above approximately 160 nm, deuterium lamp irradiance decreases in comparison to the Sun. The facility is a cryopumped vacuum chamber that achieves a system pressure of approximately 5310(exp -6) torr. It contains four individual VUV-exposure compartments in vacuum, separated by water-cooled copper walls to minimize VUV radiation and any sample contamination cross interactions between compartments. Each VUV-exposure compartment contains a VUV deuterium lamp, a motor-controlled sample stage coupled with a moveable cesium iodide VUV phototube, and two thermocouples for temperature measurement. The vacuum chamber and exterior equipment is shown. Each VUV lamp is located at the top of the chamber with its projection-tube pushed through an O-ring compression fitting. The lamp assemblies are located on ports that can be isolated from the rest of the vacuum chamber, permitting maintenance or replacement of the lamps without breaking vacuum in the main chamber where the samples are located. A view of two of the four interior VUV-exposure compartments, including the moveable sample stages and detector holders is also shown. Glenn is using this facility to support testing of Next Generation Space Telescope sunshield materials that is being led by the NASA Goddard Space Flight Center and to develop an understanding of the wavelength, intensity, and temperature dependence of VUV-induced polymer degradation.

Dever, Joyce A.↗
NASA NTRS2002

Simulated Space Vacuum Ultraviolet (VUV) Exposure Testing for Polymer Films

Vacuum ultraviolet (VUV) radiation of wavelengths between 115 and 200 nm produced by the sun in the space environment can cause degradation to polymer films producing changes in optical, mechanical, and chemical properties. These effects are particularly important for thin polymer films being considered for ultra-lightweight space structures, because, for most polymers, VUV radiation is absorbed in a thin surface layer. NASA Glenn Research Center has developed facilities and methods for long-term ground testing of polymer films to evaluate space environmental VUV radiation effects. VUV exposure can also be used as part of sequential simulated space environmental exposures to determine combined damaging effects. This paper will describe the effects of VUV on polymer films and the necessity for ground testing. Testing practices used at Glenn Research Center for VUV exposure testing will be described including characterization of the VUV radiation source used, calibration procedures traceable to the National Institute of Standards and Technology (NIST), and testing techniques for VUV exposure of polymer surfaces.

Dever, Joyce A.↗
DOE OSTI2021

Large area vertical Ga 2 O 3 Schottky diodes for X-ray detection

In this work, the Schottky barrier diodes were fabricated from a bulk Sn-doped (001) n-type Ga 2 O 3 substrate with a Si-doped epitaxial layer grown by hydride vapor phase epitaxy (HVPE), which demonstrate a good response to X-rays. Circular metal contacts with diameters ranging from 50 to 1500 um and square metal contacts ranging from 100 X 100 to 1600 X 1600 um 2 were deposited on the wafer. The devices were characterized for their electrical performance including forward current–voltage (FIV), reverse current–voltage (RIV), and capacitance-voltage (CV) measurements. The best device showed a breakdown voltage of –804 V and the devices tested had an average ideality of 1.12. The devices exhibited a clear response to X-rays even at zero bias with an experimentally observed response time 1.03 s and a linear response of detector signal to the X-ray dose rate. The experimentally observed device response time improved to 0.25 s when bias voltage is applied. The device also survived a long-term stability test of over 2 h under a constant X-ray irradiation. The sensitivity and the lower limit of detection for X-ray by Ga2O3 epitaxial Schottky detectors were discussed and determined as 43.5 C/mGy cm –2 at –200 V and 8.31 nGy Air /s, respectively.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2026

Prediction of Creep-Induced Strain Using a Symbolic Regression-Based Model

Material creep under high-temperature conditions limits the lifetime and safety of structural systems such as advanced nuclear reactors. Conventional creep testing is slow and often produces inconsistent results across nominally identical experiments, making lifetime prediction uncertain. Here, to address these challenges, this work develops a data-driven symbolic regression (SR) model that consolidates results from duplicate creep tests and predicts the remaining strain-time curve of an ongoing experiment. The method uses piece-wise multi-objective SR with physical constraints to generate analytic, interpretable functions describing transient creep strain. Applied to Inconel Alloy 617 data, the approach achieved relative mean absolute errors of 1.0–9.5%, providing closed-form predictions of strain evolution. These results demonstrate a first step toward reducing the duration and cost of long-term creep testing while retaining physically interpretable model forms.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Application of an Embedded Fracture and Borehole Modeling Approach to the Understanding of EGS Collab Experiment 1

EGS Collab is a series of meso-scale experiments and associated numerical simulation activities being funded by the United States Department of Energy, Geothermal Technologies Office (GTO) to investigate enhanced geothermal system processes under in-situ stress and slightly elevated temperature conditions. This project is designed to provide scientists and engineers with immediate access to impermeable rock at scales larger than possible in the laboratory, but generally smaller than those for commercial production. Immediate access to rock is provided via the existing drifts of the former Homestake Gold Mine, now operated as the Sanford Underground Research Facility in Lead, South Dakota. The objectives of the EGS Collab project are to develop well controlled fracture networks between injector and producer boreholes using normal and shear stimulation for permeability enhancement. The first experimental site was located off the West Access drift on the 4850 Level (4850 feet below ground surface) in phyllite of the Precambrian Poorman formation, and involved the creation of a fracture network comprising a combination of hydraulic and natural fractures. A second experimental site is now being considered near the battery alcove on the 4100 Level in amphibolite and rhyolite of the Yates Unit. Data generated during these experiments will be compared against predictions of a suite of computer codes specifically designed to solve problems involving coupled thermal, hydrological, geomechanical, and geochemical processes. Comparisons between experimental and numerical simulation results will provide code developers with direction for improvements and verification of process models, build confidence in the suite of available numerical tools, and ultimately identify critical future development needs for the geothermal modeling community. Moreover, conducting thorough comparisons of models, modelling approaches, measurement approaches and measured data, via the EGS Collab project, will serve to identify techniques that are most likely to succeed at the Frontier Observatory for Research in Geothermal Energy (FORGE), the GTO’s flagship EGS research effort. Experiment 1 has comprised a series of successful tests, including a long-term chilled-water circulation test, but the testbed has two atypical EGS elements. Active ventilation in the adjacent drift over a 50-year period cooled the testbed rock mass and hydraulic fracturing intersected monitoring boreholes making them conduits for fluid flow. Numerical simulations executed in support of the design of the EGS Collab Experiment 1, computed a radial temperature distribution and stress gradient orthogonal to the drift axis, resulting in the forecast of an oblong hydraulic fracture geometry, extended in the direction of the drift from the stimulation borehole. This paper describes the numerical simulation of long-term chilled-water circulation test with an embedded fracture and borehole modeling approach. The principal objective of the simulation work is show agreement between experimental observations in terms of production fluid temperatures, monitoring borehole temperatures, injection and production pressures, and tracer recoveries using a single conceptual model for the fracture network, using characterization and monitoring data generally available for EGS. A secondary objective is to improve the numerical simulation result comparisons with additional data available from the broader monitoring equipment within the testbed versus deeper, hotter, and more remote EGS. One complicating factor for comparisons between the numerical simulation results and experimental observations, is the Joule-Thomson heating associated with large pressure drops across the fracture network.

numerical simulation, embedded fractures and boreh↗