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At least 235 records · Page 13

Demonstration of NEAMS Multiphysics Tools for Fast Reactor Applications

The SHARP toolkit is a high-fidelity reactor simulation tool developed under the U.S. Department of Energy, Office of Nuclear Energy Advanced Modeling and Simulation (NEAMS) Campaign. SHARP toolkit is comprised of the neutronics module PROTEUS thermal hydraulics module Nek5000, and structural mechanics module Diablo. During FY17 and FY18, the PROTEUS and Nek5000 components of SHARP were applied to solve challenging sodium-cooled fast reactor (SFR) problems. In particular, selected hot channel factors (HCF) for a prototype metal-fueled SFR design (the AFR-100) were analyzed in high fidelity, and the “SHARP zooming capability” for SFRs was developed and demonstrated to reduce computational expense for full core problems in cases where detailed data is needed in selected fuel assemblies. After the previous success applying SHARP to challenging SFR problems, the focus in FY19 and FY20 expanded to additional fast reactor applications including lead cooled fast reactors (LFR) and sodium cooled fast reactors (SFR). The specific technical tasks were (1) assessment of hot channel factors for LFR, for which no data currently exists, and (2) demonstration of zooming capability in assemblies of the Versatile Test Reactor (VTR). First-of-a-kind hot channel factor (HCF) estimation for LFR with high fidelity codes (PROTEUS/Nek5000) was successfully demonstrated in this study which began in FY19 and continued in FY20. Selected HCF were computed and compared with SFR data (AFR-100, EBR-II). The findings confirm that different reactor types, design parameters and uncertainties lead to different HCFs. Careful estimation of HCF for a specific design is necessary to obtain appropriate HCFs. In addition to improvement in HCF accuracy, high fidelity tools generate data to help the designer better understand the mechanism of the impact from these uncertainties. For example, the impact of cladding thickness manufacturing tolerance resulted in non-intuitive effects in the corner pins of the LFR assembly. This procedure of computing HCF using high fidelity models shows promise and flexibility for being repeated for any arbitrary reactor of choice. Along with the application on SFR and LFR, the capability of the tools has also been matured to deal with different reactor types and designs. Progress was made towards extending the previously demonstrated SHARP zooming capability to non-fueled SFR assemblies. In particular, in FY19 a gamma transport capability was implemented in both high fidelity PROTEUS solvers in order to accurately account for heat deposition caused by gamma particles, which accounts for ~10% of total core power. Neutronics verification cases were carried out for a candidate Versatile Test Reactor (VTR) design using the new gamma transport capability in PROTEUS. Comparisons were made with continuous energy MCNP calculations and shown to agree well. The models for the full core design with heterogeneous control and fuel assemblies is in progress for PROTEUS-SN and completed with MCNP. The MCNP power distributions were transferred to Nek5000 to perform thermal hydraulic calculations of the control and fuel assembly.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Catastrophic Cooling Instability in Optically Thin Plasmas

The solar corona is the prototypical example of a low-density environment heated to high temperatures by external sources. The plasma cools radiatively, and because it is optically thin to this radiation, it becomes possible to model the density, velocity, and temperature structure of the system by modifying the MHD equations to include an energy source term that approximates the local heating and cooling rates. The solutions can be highly inhomogeneous and even multiphase because the well-known linear instability associated with this source term, thermal instability, leads to a catastrophic heating and cooling of the plasma in the nonlinear regime. Here we show that there is a separate, much simpler linear instability accompanying this source term that can rival thermal instability in dynamical importance. The stability criterion is the isochoric one identified by Parker (1953), and we demonstrate that cooling functions derived from collisional ionization equilibrium are highly prone to violating this criterion. If catastrophic cooling instability can act locally in global simulations, then it is an alternative mechanism for forming condensations, and due to its nonequilibrium character, it may be relevant to explaining a host of phenomena associated with the production of cooler gas in hot, low density plasmas.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Exponential acceleration of macroscopic quantum tunneling in a Floquet Ising model

The exponential suppression of macroscopic quantum tunneling (MQT) in the number of elements to be reconfigured is an essential element of broken symmetry phases. This suppression is also a core bottleneck in quantum algorithms, such as traversing an energy landscape in optimization, and adiabatic state preparation more generally. In this work, we demonstrate exponential acceleration of MQT through Floquet engineering with the application of a uniform, high frequency transverse drive field. Using the ferromagnetic phase of the transverse field Ising model in one and two dimensions as a prototypical example, we identify three phenomenological regimes as a function of drive strength. For weak drives, the system exhibits exponentially decaying tunneling rates but robust magnetic order; in the crossover regime at intermediate drive strength, we find polynomial decay of tunnelling alongside vanishing magnetic order; and at very strong drive strengths both the Rabi frequency and time-averaged magnetic order are approximately constant with increasing system size. We support these claims with extensive full wavefunction and tensor network numerical simulations, and theoretical analysis. An experimental test of these results presents a technologically important and novel scientific question accessible on NISQ-era quantum computers.

Grattan, George↗

Modeling Time-Dependent Surrogates of Additive-Manufactured Nuclear Fuels Processes

Additive manufacturing (AM) technology is being increasingly adopted in a wide variety of application areas for its ability to rapidly produce, prototype, and customize designs. Recently, a hybrid AM technique was successfully developed at Idaho National Laboratory (INL) to manufacture nuclear fuels [1]. Despite the advantages, this AM technique needs optimization due to defects from a highly complex melting and sintering process. The complex metallurgical phenomena during AM processes are strongly related to parameters such as applied laser power, traveling speed, and scan style, which could lead to differences in density, residual stress, crystallographic texture, and mechanical properties. In addition, stochastic variations in laser energy interaction and associated multiscale/multiphysics phenomena cause variations in microstructure evolution and mechanical properties. Currently, researchers at INL are focusing on developing a comprehensive modeling framework, leveraging INL’s simulation tools MOOSE/MARMOT/BISON/RAVEN [2-4] to describe all steps of this AM process across multiple length scales. Although this advanced framework plays a critical role in enabling enhancements to traditional trial and error approaches for design and optimization of nuclear fuel materials, it remains computationally intense, limiting its use in sensitivity and optimization analysis. In this case, an accurate and inexpensive surrogate becomes an effective tool for providing a tractable approximation of the underlying underline physics. Surrogate models generally not based on the physics of a system are purely mathematical models used to capture the relationships between specific system inputs and outputs. Popular approaches, including neural networks [5], response surfaces [6], and subspace-based reduced order models [7], have been applied to a wide range of disciplines, such as nuclear reactor design, aerospace design and automotive design. In this summary, we employ advanced time-dependent surrogate models such as high-dimensional model representation (HDMR) [8] and physics-informed deep neural network (PINNs) [9] to accelerate the design and optimization of AM process.

42 ENGINEERING↗

Development of a near-isothermal transcritical CO 2 compression system with a liquid piston compressor

Compressors are critical components in vapor compression cycle systems, significantly contributing to energy consumption. As global demand for HVAC&R systems rises, enhancing compressor efficiency becomes increasingly vital. This paper introduces a novel liquid piston compressor integrated with a gas cooler for the transcritical CO 2 refrigeration cycle. The liquid piston enables CO 2 refrigerant compression within various types of heat exchangers, facilitating the transfer of compression heat to the heat transfer fluid. By releasing significant heat, this compressor allows for removing or downsizing the traditional gas cooler in the refrigeration system. This paper presents the experimental performance of the first near-isothermal compressor utilizing a liquid piston in a vapor compression cycle. The critical parameters affecting heat transfer are analyzed by using a 1-D simulation model to achieve a near-isothermal compression process. The results show that the developed prototype successfully reduced the compression temperature increase from 95 K to 10 K, achieving 90 % isothermal efficiency. Furthermore, the 1-D simulation results suggest the smaller internal diameter tubes benefit the isothermal efficiency the most.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Fundamental limit of jet tagging

Identifying the origin of high-energy hadronic jets (jet tagging) has been a critical benchmark problem for machine learning in particle physics. Jets are ubiquitous at colliders and are complex objects that serve as prototypical examples of collections of particles to be categorized. Over the last decade, machine learning-based classifiers have replaced classical observables as the state of the art in jet tagging. Increasingly complex machine learning models are leading to increasingly more effective tagger performance. Our goal is to address the question of convergence—are we getting close to the fundamental limit on jet tagging or is there still potential for computational, statistical, and physical insights for further improvements? We address this question using state-of-the-art generative models to create a realistic, synthetic dataset with a known jet tagging optimum. Various state-of-the-art taggers are deployed on this dataset, showing that there is a significant gap between their performance and the optimum. Our dataset and software are made public to provide a benchmark task for future developments in jet tagging and other areas of particle physics.

Artificial intelligence↗

Modeling and Characterization of TES-Based Detectors for the Ricochet Experiment

Coherent elastic neutrino-nucleus scattering (CE nu NS) offers a valuable approach in searching for physics beyond the standard model. The Ricochet experiment aims to perform a precision measurement of the CE nu NS spectrum at the Institut Laue-Langevin nuclear reactor with cryogenic solid-state detectors. The experiment plans to employ an array of cryogenic thermal detectors, each with a mass of around 30 g and an energy threshold of below 100 eV. The array includes nine detectors read out by transition-edge sensors (TES). These TES-based detectors will also serve as demonstrators for future neutrino experiments with thousands of detectors. In this article, we present an update on the characterization and modeling of a prototype TES detector.

Chang, C. L.↗

Performance Assessment of High Efficiency Variable Speed Air-Source Heat Pump in Cold Climate Applications

This project was part of an effort by ComEd's emerging technology program to evaluate the energy saving potential of new energy efficiency technologies. The focus of this technology assessment was to determine energy and peak demand savings potentials of a high efficiency variable speed, air-source, split system heat pump designed for cold climate applications. The results of this technology assessment will be used by CLEAResult to develop a new energy efficiency measure for Commonwealth Edison Company's incentive programs. The project utilized the National Renewable Energy Laboratory's (NREL) Thermal Test Facility to experimentally characterize cooling and heating performance of a high efficiency heat pump split system under varying outdoor climate conditions. The selected climate conditions represented summer and low temperature winter conditions in ComEd's service territory. The laboratory experimentation results were used to develop equipment performance curves required by EnergyPlus hourly simulation engine. Using typical meteorological year 3 weather data for the Chicago O'Hare airport, hourly building simulations (using the EnergyPlus engine) was utilized to estimate the annual energy savings of the high efficiency heat pump in comparison to a standard efficiency unit in the following U.S. Department of Energy (DOE) building codes program energy prototypes: Single-family residence; Strip mall; and Low-rise office.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Transient testing of uranium silicide fuel in zircaloy and silicon carbide cladding

Using the newly restarted Transient Reactor Test (TREAT) facility at Idaho National Laboratories, fresh (unirradiated) U 3 Si 2 fuel pellets were tested under reactivity-initiated accident conditions in dry helium capsules. These tests were performed with total energy depositions sufficient to induce melting of the U 3 Si 2 fuel pellets based on available thermophysical property data. The instrumented experiments utilized in-pile thermocouples and infrared pyrometers to measure the cladding temperature during the transient, which are in reasonable agreement with predicted peak cladding temperatures using a simple BISON fuel performance model. This same model is then used to predict expected cladding stresses during the transients in areas where pellet cladding interaction is expected. It was shown that for transient energy depositions up to 528J/g rod like geometry of the test articles was maintained. While it is acknowledged that more confirmatory testing is required in more prototypic environments, these first of their kind experiments have demonstrated that unirradiated U 3 Si 2 fuel and unirradiated SiC-SiC claddings can likely retain a “rod like” geometry for transient energy depositions up to 528J/g.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Convex Optimization with Smart Grid Examples

In this talk, we give an overview of the field of convex optimization and work through four canonical problems that relate to electrical power systems and smart grids. The purpose of these examples is to demonstrate the breadth of applications of convex optimization in energy research and to show that toy versions of these problems can be solved in just a few lines of code, indicating the scale and complexity of problems that can be tackled with a more detailed treatment. We emphasize the cvxpy modeling language as a foundational technology that enables rapid development and prototyping of convex optimization problems, allowing researchers to focus on model development rather than get caught in the weeds of numerical and code implementation.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Linear thermomagnetic energy harvester for low-grade thermal energy harvesting

Low-grade thermal energy, either from waste heat or from natural resources, constitutes an enormous energy reserve that remains to be fully harvested. Harvesting low-grade heat is challenging because of the low Carnot efficiency. Among various thermal energy harvesting mechanisms available for capturing low-grade heat (temperature less than 100 degrees C), the thermomagnetic effect has been found to be quite promising. In this study, we demonstrate a scalable thermomagnetic energy harvester architecture that exhibits 140% higher power density compared to the previously published spring-mass designs. The alternating force required to oscillate the thermomagnetic mass is generated through the interaction between two magnetic forces in opposite directions. We employed numerical modeling to illustrate the behavior of a thermomagnetic device under different operating conditions and to obtain the optimal hot-side and cold-side temperatures for continuous mode operations. A miniaturized thermomagnetic harvester was fabricated and experiments were conducted to systematically evaluate the performance. The prototype was found to exhibit an oscillation frequency of 0.33 Hz, a work output of 0.6 J/kg/cycle, and a power density of 0.2 W/kg of gadolinium under the temperature difference of 60 K.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Additive Manufacturing for Powering the Blue Economy Applications: A Tidal Turbine Blade Case Study: Preprint

As the marine renewable energy industry continues to expand, innovation in the manufacturing space must grow accordingly to reduce costs and ensure the economic feasibility of new technologies. Additive manufacturing, more commonly known as 3D printing, provides an alternative for rapid prototyping of marine hydrokinetic technologies, particularly supporting Powering the Blue Economy initiatives of the U.S. Department of Energy Water Power Technologies Office. This study explores the application of additive manufacturing in the development of marine hydrokinetic structures, focusing on material and printing method selection, design, and analysis of a 3D-printed spar for an axial-flow tidal turbine blade. Corrosion-resistant metals were deemed ideal due to the loads and harsh marine environment the blade would experience. Laser metal deposition methods were determined to be the most effective and scalable for the considered scale. The designed spar adapts its geometry to the blade - a feature uniquely suited to additive manufacturing - and is intended to serve as the blade's primary structural component. A finite element model was used to study stresses and deformations under loading conditions. The spar was manufactured using 316L stainless steel through direct energy deposition, and defects were assessed and recorded. Future efforts will include mechanical testing of the spar. This research establishes a benchmark process for using additive manufacturing in developing marine hydrokinetic structures, paving the way for future optimization and techno-economic analysis.

additive manufacturing↗

Accurate Electron-Phonon Interactions from Advanced Density Functional Theory

Electron-phonon coupling (EPC) is key to understanding charge transport, band renormalization, and superconductivity in energy materials, including correlated transition-metal oxides, ferroelectric perovskites, optoelectronic semiconductors, and phonon-mediated superconductors. Although first-principles density functional theory (DFT)-based EPC calculations are used widely, their predictive power is limited by the accuracy, transferability, and efficiency of the underlying exchange-correlation functionals. These limitations become exacerbated in complex 𝑑- and 𝑓-electron materials, where beyond-DFT approaches and additional corrections, such as the Hubbard 𝑈, are commonly invoked. Here, using the examples of Co⁢O and Ni⁢O, we show how the 𝑟 2 SCAN density functional correctly captures strong EPC effects in transition-metal oxides without requiring the introduction of Hubbard 𝑈 parameters. We also find that 𝑟 2 SCAN successfully describes the subtle interplay between ionic and covalent bonding, and strong EPC effects in the low-temperature rhombohedral phase of the prototypical ferroelectric Ba⁢Ti⁢O 3 , without requiring Hubbard 𝑈 and intersite 𝑉 corrections. We further demonstrate the ability of 𝑟 2 SCAN to accurately model the EPC of the main-group semiconductor Ga⁢As and the phonon-mediated superconducting properties of Mg⁢B 2 , with reliable electronic bands and phonons. Our study establishes 𝑟 2 SCAN-based EPC as a transferable, parameter-free, and computationally efficient framework for predictive material-specific modeling of EPC in energy materials, and opens a practical route toward high-throughput screening of superconductors, thermoelectrics, optoelectronic semiconductors, and oxide electrodes and catalysts.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

Durable and Low-Cost Fractal Structured Multifunctional Coatings for Next-Generation CSP

Fractal coatings on various low-cost and high-temperature metallic substrates such as SS316, SS347, In800H, In740H, In625, Haynes 230, etc. were fabricated employing our patented novel electrodeposition process at various deposition potentials and deposition times, as well as chemical etching. The best combination of the materials and processing conditions were co-optimized for the reliable and repeatable fabrication of the multifunctional coatings. Surface morphologies were examined using SEM and AFM, and fractal characterization was done using a 3D optical surface profiler. Fractal dimension was used to identify successful fabrication and material parameters. The mechanical durability of the coatings was evaluated using several standardized tests, such as sand abrasion (ASTM D968) and adhesion (ASTM D3359), to fully characterize and demonstrate the mechanical durability of the fabricated surfaces. HTF immersion tests on the fractal multifunctional coatings were conducted based on a modification of the ASTM D870, which is established for static water immersion testing. To calculate the corrosion rates and descaled weight loss of the samples subjected to thermal exposure for different time durations (100 h, 300 h, 500 h, and optionally 750 h) to estimate the corrosion rate. While protecting the substrates from corrosion is an important goal, an allied goals is also to examine the post-corrosion temperature stability and properties of the molten salts themselves due to the dissolution of the constituents of the alloys and the corrosion products from the coatings that cause “fouling” of the molten salts. Fouling characteristics of the different molten salt HTFs exposed to coated and uncoated substrates were investigated. Finally, considering a prototype molten salt/sCO2 heat exchanger, cost/performance model is developed to demonstrate that the coatings on low-cost alloys such as stainless steel provide lower levelized cost of heat exchanger compared to high nickel content Ha230.

14 SOLAR ENERGY↗

Advancing the HERO WEC Through Integrated Modeling, Testing, and Field Deployments

The Hydraulic and Electric Reverse Osmosis Wave Energy Converter (HERO WEC) was developed by the National Laboratory of the Rockies as a modular platform for advancing wave-powered desalination technologies. Designed to operate in either a hydraulic or electric configuration, the system enables direct comparison of mechanical-to-water and electrical-to-water conversion pathways using a single hardware architecture. Deployments in 2022 and 2024 at the Jennette's Pier test site in North Carolina demonstrated freshwater production between 60 and 300 gallons per day, including successful operation in wave heights as low as 0.25 m. A structured evaluation approach combining numerical modeling of hydrodynamic and power take-off response, controlled laboratory testing, and in-ocean field deployments has been used to characterize and refine system performance. Specifically, insights from these efforts are now informing the second-generation HERO WEC (V2) to increase robustness and overall survivability. Changes from the original prototype include improved drivetrain components, refined geometry, enhanced control systems, and design. The HERO WEC platform continues to serve as an open-access research asset supporting broader marine energy and desalination development.

16 TIDAL AND WAVE POWER↗

Higher Efficiency, Demand Flexible Refrigerator with On-Demand Micro-Vibrational De-icing Technology

Refrigerator technology has advanced significantly over the last couple of decades. Today’s refrigerators use only about 25% of the energy that was required to power models built in 1975. Even as they continually improve efficiency to meet standards, refrigerators have increased in size by almost 20%, added energy-consuming features such as through-the-door ice, and provide more benefits than ever before. However, a few challenges and technology gaps are preventing further improvement of the demand responsiveness and efficiency of the refrigerators. One of the major technology gaps in existing refrigerators is their outdated de-icing process. When the evaporator generates frost, an old-fashioned resistive heating element melts the ice. Most refrigerators have a timed defrost cycle, rather than an active system that could monitor the state of the frost. In these systems, not only is the precious electricity used at its least efficient form of conversion (direct conversion of electricity to heat), but also all the latent heat associated with the ice is wasted during the melting process. On top of that, the refrigerator needs to work harder to pull the temperature down after defrosting, and, last but not least, the food quality is severely impacted by the temperature swings during the defrost cycle. According to a study, the EU alone wastes 89 million tons of food in the supply chain every year. Any temperature swing during defrosting (about 6F according to Emerson for low-temperature cases) can negatively impact the shelf life of meat and other products for multiple days. All these issues can happen during the peak demand time of the electric grid. Unlike the conventional systems, the proposed novel advanced micro-vibrational deicing process uses no heat for defrosting. Instead, it uses the micro vibrations generated by a piezoelectric or vibration-generating module to mechanically break ice from the heat exchanger almost instantaneously. The project titled “Higher Efficiency, Demand Flexible Refrigerator with On-Demand Micro-Vibrational De-icing Technology, performed by Ultrasonic Technology Solutions, LLC (UTS) of Knoxville, TN, in collaboration with Emerson (now Copeland), represents the final phase of a multi-year effort funded under the U.S. Department of Energy’s Building Technologies Office (BTO) BENEFIT FOA 2020. Initiated on October 1, 2021, and completed after a nine-month no-cost extension ending September 30, 2025, this project aimed to develop and validate a novel micro-vibrational mechanical defrosting system, achieving more than 25% improvement in defrosting energy efficiency over conventional baseline defrosting technologies. Over sixteen quarters, the project advanced from fundamental ice-mechanical characterization and prototype development to full-scale system integration and validation. Initial efforts established project management infrastructure and characterized ice adhesion properties, followed by the design and fabrication of early aluminum-based prototypes for resonance frequency testing. Subsequent quarters saw rapid technical progression, including the identification of optimal piezoelectric and motor-based vibration mechanisms, the demonstration of effective de-icing over 6x6-inch aluminum surfaces. The team achieved its Go/No-Go milestone by exceeding the 25% energy-efficiency improvement target—reaching up to 3,340% under optimized conditions—and later confirmed that motor-driven systems offered superior performance and energy efficiency compared to piezoelectric alternatives. Continued refinement led to the development of amplifier systems on printed circuit boards, improved control and instrumentation hardware, and integration into full-scale heat exchanger (HX) prototypes at both UTS and Copeland facilities. Multiple vibration-mounting studies and frost-growth experiments guided mechanical optimization and noise-mitigation strategies, achieving a 17.5 dB reduction in sound pressure level and verifying robust mechanical performance. Advanced analyses, including modal and harmonic simulations, established a quantitative understanding of vibrational behavior and de-icing efficiency across >1000 cm² systems. The final project phase successfully demonstrated scalable integration within reach-in and chest freezer prototypes, confirmed >25% efficiency improvements in large-area systems, and completed a comprehensive business model and scale-up strategy identifying electric defrost systems as the primary beachhead market. The culmination of this DOE-supported effort establishes micro-vibrational defrosting as a viable, high-efficiency, low-noise, and demand-flexible de-icing technology, paving the way for commercial deployment and broader application in next-generation refrigeration systems.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Celeritas R&D Report: Accelerating Geant4

Celeritas is a new Monte Carlo (MC) detector simulation code designed for computationally intensive applications on high-performance heterogeneous architectures. In the past two years Celeritas has advanced from prototyping a Graphics Processing Unit (GPU)-based single physics model in infinite medium to implementing a full set of electromagnetic (EM) physics processes in complex geometries. The current release of Celeritas, version 0.4, has incorporated full device-based navigation, an event loop in the presence of magnetic fields, and detector hit scoring. New functionality incorporates a scheduler to offload electromagnetic physics to the GPU within a Geant4-driven simulation, enabling straightforward integration of Celeritas into the high energy physics (HEP) experimental frameworks CMSSW and ATLAS FullSimLight. On the Perlmutter supercomputer, Celeritas performs EM physics between 3× and 18× faster using the machine’s Nvidia GPUs compared to using only CPUs, corresponding to an electrical power efficiency up to a factor of 5. When running a multithreaded Geant4 ATLAS test beam application with full hadronic physics, using Celeritas to accelerate the EM physics results in an overall simulation speedup of 1.7–2.2× on GPU and 1.2× on CPU. In a CMS test application using tt¯ events and the prototype Run 4 configuration, compared to Geant4 CPU, Celeritas with a Nvidia A100 improves overall throughput up to a factor of 2.7× but cannot be efficiently shared with more than 8 cores.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

Optimization and Experimental Validation of Annular Finned PCM-HX for a Domestic Hot Water Heater Application

The load profile for domestic water heating is time-dependent and can result in high energy demand during peak operating times. Shifting this peak load can have significant environmental and economic impacts. Phase change material (PCM)-based thermal energy storage (TES) is a potentially useful technology for peak load shifting in domestic hot water (DHW) applications thanks to its high latent heat and energy density. In this study, an annular finned-tube PCM-HX design concept was optimized for a load-shifting TES unit to meet the Department of Energy standard for a medium-usage DHW heater using a resistance-capacitance model (RCM) integrated with a Multi-Objective Genetic Algorithm. The optimized design comprised 70 identical annular finned-tube PCM-HX units connected in parallel and utilizing RT62HC as the PCM. A single PCM-HX unit was prototyped and tested in a vertically oriented setup with upward heat transfer fluid (HTF) flow. The hot water supply time was defined based on a cutoff temperature of 51.7°C. The as-designed mass flow rate (1.5 g/s) was tested to assess the performance of the prototyped PCM-HX unit for RCM validation. For the experimental investigation, RTD sensor bundles measured HTF temperature at the PCM-HX inlet and outlet, and a Coriolis flow meter accurately measured the HTF mass flow rate. The simulated discharging power underpredicted the experimental result by about 12%, and the simulated hot water supply time underpredicted the experimental result by approximately 13% for the as-designed mass flow rate (1.5 g/s). The average deviation of the hot water supply temperature between the experimental and RCM results during the complete PCM solidification process was 1.3 K for the as-designed mass flow rate. The overall good agreement between the experimental and RCM results provides confidence that computationally efficient models such as RCM can be utilized for design optimization of PCM-HXs.

42 ENGINEERING↗