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DOE OSTI2023

Experimental and Numerical Investigation of Flow Boiling in Additive Manufactured Foam Structures With Vapor Pathways

Abstract The unique properties of metal foams make them potential candidates for a range of applications, including microsystem thermal management. Using additive manufacturing to create foam-type structures can improve upon prior thermal solutions by eliminating thermal interface materials and allowing for customization/local control of parameters. In the present investigation, flow boiling in additive-manufactured metal foams is investigated both experimentally and numerically. Two test samples, one with uniform structure and the other with pathways for vapor removal, are compared both experimentally and numerically. A conjugate computational fluid dynamics and heat transfer (CFD-HT) model utilizing a three-dimensional volume of fluid (VOF) model with accompanying evaporation/condensation model provided in-depth visualization of the boiling flow phenomena. The experiments generated the thermohydraulic performance over a range of heat fluxes, demonstrating that the sample incorporating dedicated vapor pathways performed better in both pressure and heat transfer performance metrics compared to the uniform foam. Additionally, negative system-level effects (i.e., hydraulic oscillations) were shown to be abated using the vapor removal structures. The numerical model yielded further insight into the factors contributing to the improved performance. Results indicated the pathways functioned as vapor removal channels, allowing the generated vapor to vent from the foam structure into the lanes. Further computational investigations demonstrated changes in flow regimes, where the addition of vapor channels caused the flow to change from churn to annular. Bubble behavior unique to the vapor pathway structure was studied, showing stagnant regions that eject vapor into the channel.

Engineering↗

DOE OSTI2020

Multi-Scale Thermal Analysis for Design of SiC-Based Medium Voltage Motor Drive: Preprint

This paper describes a multi-scale thermal analysis approach for the design of an air-cooled 1.7-kV SiC MOSFET-based medium-voltage variable-speed motor drive. The National Renewable Energy Laboratory supported the project objectives by providing thermal management design support to the project partner The Ohio State University (OSU). The scope of the models and limited resources required efficient and flexible thermal models to be developed. Two modeling techniques are described that significantly reduced model run time and enabled more complex models to be run faster while retaining needed accuracy. The first technique uses the effectiveness-NTU method to extract convection boundary conditions from a computational fluid dynamics (CFD) model that can be applied to a fast-running finite element analysis model. The second is a porous media technique that enables system-level CFD simulations that incorporate effects from heat exchangers (e.g., pin fin heat sinks) that run in a fraction of the time required for fully resolved CFD simulations. The multi-scale approach to the thermal analysis enabled fast and accurate simulation for the converter design ranging from the die level up to the full system with 36 submodules. The modeling results were validated against experimental data from system tests performed by OSU.

DIRECT ENERGY CONVERSION↗

DOE OSTI2025

High-Temperature Aquifer Thermal Energy Storage (HT-ATES) Projects in Germany and the Netherlands—Review and Lessons Learned

Aquifer thermal energy storage (ATES) is a concept that can help to address heating and cooling needs through the use of the subsurface as a seasonal thermal energy storage (STES) system. Over 2800 ATES systems have been deployed with storage temperatures typically below 25 °C and only a few with higher temperatures (>40 °C), which would increase the energy density and utility of the stored thermal fluids. Until now, only a few high-temperature aquifer thermal energy storage (HT-ATES) projects have been initiated and are still in operation. These HT-ATES projects have encountered a range of technical and non-technical challenges. This study reviews ten such projects: four in Germany and six in the Netherlands. The non-technical issues include public acceptance, a lack of regulatory framework for these systems, managing overlapping uses of the subsurface, managing changes with the providers and off-takers of thermal energy, and obtaining financing to implement these projects. Common technical issues include geological factors such as incomplete characterization of the subsurface and reservoir heterogeneity; geochemical issues such as mineral scaling, corrosion, and biofouling; lower than expected thermal recovery; and issues with system design and reliability. This review highlights benefits and challenges faced by HT-ATES projects with the goal to use the lessons learned to improve the siting, design, development, and operation of such systems. Recommendations include improved initial subsurface site characterization, use of coupled process models to optimize system design and predict system performance, cascaded uses of stored thermal energy to better utilize the stored heat, monitoring networks to provide feedback on system performance, and expanded system scale to allow for continued operation even when maintenance of some system components is required. Techno-economic modeling and risk analysis could be used to optimize such HT-ATES project design and identify key factors that will affect sustained economic viability. In addition, design flexibility is important for these systems to allow for changing conditions regarding the supply and demand of thermal energy. Adopting these findings should improve the performance and reduce the risks for future HT-ATES projects worldwide.

15 - GEOTHERMAL ENERGY↗

DOE OSTI2022

Geothermal Reserve Pits: Considerations for Installation on BLM-Administered Lands

Reserve pits, also known as sumps, are a common aspect of geothermal drilling operations. This paper describes the Bureau of Land Management's regulatory authorities and key environmental considerations associated with geothermal reserve pits. Reserve pit design, the need for environmental compliance measures, and reclamation approaches will vary depending on site-specific conditions. Groundwater and wildlife impacts are the most common environmental considerations related to reserve pits. In some cases, regulations or groundwater or soil conditions necessitate the use of a synthetic liner. However, the chemical composition of most geothermal drilling fluids and muds, completion fluids, and produced fluids that are discharged to reserve pits does not warrant pit liners. The potential for hazardous fluids, high water temperatures, and entrapment are concerns for wildlife. Common wildlife impact avoidance and mitigation measures include fencing, netting, and escape ramps. The need for these measures depends on localized site and environmental conditions. There are requirements to reclaim reserve pits following geothermal drilling operations. Reserve pits often remain in place to accommodate multiple phases of drilling and well testing. They are eventually backfilled and decommissioned.

BLM↗

DOE OSTI2022

Multi-Pressure Rail System Design with Variable Pressure Control Strategy

This paper presents the design and the control method of a Multiple Pressure Rail system (MPR) with a variable pressure control logic that allows minimization of throttling loss, therefore, increasing the overall fluid power actuation efficiency. An MPR system allows controlling hydraulic actuators with a pressure control logic, as opposed to traditional flow control logics which are well established in mobile applications. A proper setting of the number of pressure rails and the pressure level in each rail permits optimizing the system efficiency of an MPR solution. MPR systems have been recently proposed with different purposes, but seldom adopt variable pressure control strategies to manage the pressure variations in the rails. Moreover, the related past work attempts to maximize the energy recovery during overrunning load conditions. This paper, instead, addresses the case of an MPR system that handles a multitude of hydraulic functions without significant overrunning loads, as it occurs in many mobile applications such as in agriculture. The paper first presents the design alternatives considered for the MPR system, including the supply, the control valves, and the controller. Second, a dedicated test rig is developed to support experimental activities and validations of a lumped parameter model developed within this research to develop the MPR control strategy. The results describe the operating features of the proposed MPR solution. By considering the case of a traditional LS system, the paper results also show how system efficiency can be highly improved, with energy savings in the order of 49%

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2025

COMSOL Results for the Nominal Steady-State Operation of the Proposed 95-MW LEU Silicide Core for HFIR Conversion

Engineering design studies are being performed to determine the feasibility of converting the High Flux Isotope Reactor (HFIR) from highly enriched uranium (HEU) to low-enriched uranium (LEU) fuel at Oak Ridge National Laboratory. This activity is sponsored by the Office of Reactor Conversion and Uranium Supply (ORCUS) under the auspices of the US Department of Energy National Nuclear Security Administration’s Office of Material Management and Minimization. HFIR is a very high flux, pressurized, light water–cooled and moderated, flux trap–type research reactor with a core made of involute shaped U 3 O 8 /Al cermet fuel plates and coolant channels. HFIR currently operates at a thermal power of 85 MW and supports key national and international missions in neutron scattering, isotope production, materials/fuels irradiation, neutron activation analysis, gamma irradiation, and neutrino research. Advanced multiphysics computational fluid dynamics models have been developed in the COMSOL Multiphysics software to simulate the steady-state operating conditions for the proposed low-and high-density LEU U 3 Si 2 -Al (uranium silicide dispersion) fuel designs. The COMSOL models for HFIR inner and outer fuel element models incorporate various essential inputs and physics such as spatially dependent nuclear heat deposition, multilayer heat conduction, conjugate heat transfer, turbulent flows (using Reynolds-averaged Navier Stokes turbulence models), structural mechanics (thermal–structural interactions and fuel swelling), and oxide layer build-up. This report presents the best-estimate thermal hydraulics results for the low- and high-density optimized silicide LEU core designs at 95 MW steady-state nominal operation.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2020

Experiences with a Flexible User Research Process to Build Data Change Tools

Scientific software development processes are understood to be distinct from commercial software development practices due to uncertain and evolving states of scientific knowledge. Sustaining these software products is a recognized challenge, but under-examined is the usability and usefulness of such tools to their scientific end users. User research is a well-established set of techniques (e.g., interviews, mockups, usability tests) applied in commercial software projects to develop foundational, generative, and evaluative insights about products and the people who use them. Currently these approaches are not commonly applied and discussed in scientific software development work. The use of user research techniques in scientific environments can be challenging due to the nascent, fluid problem spaces of scientific work, varying scope of projects and their user communities, and funding/economic constraints on projects.In this paper, we reflect on our experiences undertaking a multi-method user research process in the Deduce project. The Deduce project is investigating data change to develop metrics, methods, and tools that will help scientists make decisions around data change. There is a lack of common terminology since the concept of systematically measuring and managing data change is under explored in scientific environments. To bridge this gap we conducted user research that focuses on user practices, needs, and motivations to help us design and develop metrics and tools for data change. This paper contributes reflections and the lessons we have learned from our experiences. We offer key takeaways for scientific software project teams to effectively and flexibly incorporate similar processes into their projects.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2025

Solar Decarbonization of Paraffin Dehydrogenation Through Particle Heat Carriers (Final Technical Report)

This project focuses on solutions to decarbonize high-temperature catalytic processes using solar thermal heat. The primary project goal is to show the validity of a moving packed bed reactor for propane dehydrogenation using catalyst particles as the heat carrier for the reaction, which can be heated by concentrated solar energy in a particle receiver. This concept, if further developed, may provide a cost-effective pathway for converting lower value gases to important chemical precursors for industrial materials using only renewable energy. The project was divided into six tasks. In Task 1, DFT calculations were performed to understand the role of Pt and Sn in the catalytic dehydrogenation reaction. In Task 2 chemical kinetics measurements were made for several catalyst formulations at high temperatures. In Task 3, the solar absorptance of catalyst particles was compared to the absorptance of commonly used materials in particle receivers. In Task 4, numerical models were developed which could predict performance of the complete system and predict specific temperatures in the system. In Task 5, a prototype system was designed, fabricated, and tested to show the validity of the concept. Task 6 concerned project management activities. Experiments with the prototype showed repeatable thermal performance at temperatures targeted for the reaction. A limited set of tests were done with active catalyst and propane dehydrogenation, showing conversion of propane to propylene with a range of conversions and selectivities. The results are promising, and the prototype designed was reliable during testing, and the team expects that further development of the prototype would yield improved results. A numerical model framework based on coupled fluid and particle mechanics was developed with high computational efficiency using GPU calculations. The model may prove highly useful for evaluating other high-temperature particle systems. However, it was determined that simpler porous media models were good fits for the needs of the current moving packed bed concept. Data showing strong solar absorption of the particles validates the plan of using existing solar particle receivers with only a change in the particle type. Catalyst investigation showed that Pt 1 Sn 3 is the most viable candidate for developing PtSn catalysts for high temperature propane dehydrogenation, considering the balance of activity, selectivity, and deactivation. This project completed an initial study of various factors needed to incorporate a moving bed catalytic reactor for propane dehydrogenation into a concentrated solar thermal particle system. Future developments may allow this technology to be scaled up and help to use solar thermal energy to decarbonize not only the propane dehydrogenation reaction, but other gas-solid catalytic reactions at similar temperatures.

14 SOLAR ENERGY↗

DOE OSTI2022

Alkaline cation enrichment and water electrolysis to provide CO 2 mineralization and global-scale carbon management

Provided herein are methods of removing carbon dioxide from an aqueous stream or gaseous stream by: contacting the gaseous stream comprising carbon dioxide, when present, with an aqueous solution comprising ions capable of forming an insoluble carbonate salt; contacting the aqueous solution comprising carbon dioxide with an electroactive mesh that induces its alkalinization thereby forcing the precipitation of a carbonate solid from the solution and thereby the removal of dissolved inorganic carbon by electrolysis; and removing the precipitated carbonate solids from the solution, or the surface of the mesh where they may deposit. Also provided herein are flow-through electrolytic reactors comprising an intake device in fluid connection with a rotating cylinder comprising an electroactive mesh, and a scraping device and/or liquid-spray based device for separating a solid from the mesh surface.

Sant, Gaurav↗

DOE OSTI2022

Findings on Subtask 3.1 - Bakken Rich Gas Enhanced Oil Recovery Project

Total in-place oil for the Bakken petroleum system (BPS) (which includes the Bakken and Three Forks Formations) has been estimated to be 600 billion barrels (bbl). However, BPS wells have decline rates as high as 85% over the first 3 years of their lives, and primary recovery factors typically range from 3% to 10% of original oil in place. Given the low initial recovery rates, even small incremental productivity improvements could dramatically increase technically recoverable oil in the BPS. One potential solution is enhanced oil recovery (EOR) using gas injection, such as carbon dioxide (CO2) or hydrocarbon (HC) gases. While commonly used in conventional reservoirs, CO2 EOR in unconventional tight oil reservoirs has been limited to pilot tests. EOR using rich gas (mixture of methane, ethane, and propane) has also been employed in numerous pilots in several unconventional plays and has recently been successfully applied in the Eagle Ford play. If successful, large-scale gas-based EOR in the BPS could dramatically increase oil productivity and recovery factors and extend the life of the play for decades. While CO2 may be a technically suitable working fluid for EOR in the BPS, supplies are limited and costs for using CO2 in EOR pilots are prohibitively high. Meanwhile, produced gas flaring has presented challenges for BPS operators in North Dakota. Analysis conducted by the North Dakota Pipeline Authority indicates that the current gas-gathering infrastructure in North Dakota is insufficient to accommodate all of the associated gas that is produced from the BPS. The geographically isolated location of North Dakota relative to large natural gas markets, combined with suppressed natural gas prices, has made it economically challenging for industry to invest capital in expanding gas-gathering infrastructure in the state. These circumstances led to a research program conducted by the Energy & Environmental Research Center (EERC) in partnership with Liberty Resources Management Company LLC (LR) to examine the potential to use rich gas injection for EOR and mitigate flaring. A rich gas EOR pilot test was designed and executed by LR at its Stomping Horse development area in Williams County, North Dakota. From July 2018 through May 2019, a total of 160 million standard cubic feet (MMscf) of rich produced gas was injected into the BPS using five different wells in a sequential injection strategy. LR’s Leon–Gohrick drill spacing unit (DSU) was used as the test site. Regulatory oversight was provided by the North Dakota Industrial Commission (NDIC). Technical support was provided by the EERC through a series of laboratory, modeling, and field-based activities, and additional post-pilot research activities incorporated learnings from the test, developed new laboratory data, improved fracture modeling methods, and developed machine learning and big data analytics. The results from the Stomping Horse rich gas EOR pilot activities indicate that developing an effective, economical EOR approach for the BPS will require more field tests. Another key lesson learned from the Stomping Horse tests is that detailed pre- and posttest data on reservoir conditions and fluids production are essential. Robust reservoir characterization provides information that is crucial to creating realistic geomodels and conducting valid dynamic simulations of potential EOR scenarios. A detailed understanding of the completions and production history of offset wells is also necessary for valid test result interpretations. This knowledge is essential to designing the operational parameters of injectivity tests and interpreting the results. A conformance control strategy is also essential to success. Laboratory-based examinations of rich gas interactions with reservoir fluids and rocks were conducted, with an emphasis on determining the ability to mobilize oil in the tight reservoir rocks and shales of the BPS. Injection fluid composition was shown to have a positive impact on reducing reservoir oil minimum miscibility pressure (MMP), reducing interfacial tension (IFT), and altering wettability. IFT and contact angle measurements demonstrated that wettability can be altered in the presence of rich gas, suggesting the potential to improve oil recovery. Iterative modeling of surface infrastructure and reservoir performance using data generated by the various project activities was conducted. A geologic model of the Stomping Horse area was built; history-matched oil, gas, and water production was used in simulations of various EOR scenarios. Early programmatic modeling results were used to support LR’s design and operation of the EOR pilot and to provide insight regarding optimization of future commercial-scale BPS EOR design and operations. Post-pilot modeling focused on alternative methods of understanding complex fracture networks and accelerating simulation time. These led to improved simulation run times and provide excellent history-matching results. Several of these iterative models were used as the bases for developing algorithms into machine learning and big data analytics. History matching in reservoir simulation is time-consuming and computer processing-intensive. Machine learning algorithms were created, and an automated history-matching tool was developed. A large set of synthetic reservoir simulations were created to generate well responses (oil, gas, and water production, well bottomhole pressure [BHP], and tracer or propane breakthrough) for a set of EOR operating parameters that included offset well status (open or closed), injectate (rich gas or propane), injection rate, and injection well BHP. A user interface was developed to provide real-time visualization. Machine learning-based models were developed to provide rapid forecasting of well performance given a set of user-defined EOR operating parameters. These predictive models allow the user to modify the offset well status, injection rate, and injection well BHP and rapidly forecast future production performance. The combination of real-time visualization tools with real-time forecasting tools provides a framework for real-time control—operational changes that the EOR site operator can enact (e.g., changing gas injection rates) to affect the observed performance and potentially improve the EOR outcome. There is great reason to be optimistic about the future of EOR in the Bakken. The results of the laboratory studies suggest significant potential for high rates of oil mobilization using produced field gas injection under the right conditions. The results of the lab studies, combined with rigorous statistical analysis of well production data and associated modeling efforts, confirm the notion that fluid mobility within the reservoir is controlled by fractures. As more knowledge is gained about the nature and distribution of fracture networks in the Bakken, the industry will be in a better position to predict and, ultimately, influence fluid mobility. New field tests are necessary to develop a more complete understanding of those conditions. Thoughtful and creatively engineered field tests within a well-characterized geologic setting will yield the fundamental knowledge needed to take Bakken oil production to the next level. This subtask was cofunded through the EERC–U.S. Department of Energy Joint Program on Research and Development for Fossil Energy-Related Resources Cooperative Agreement No. DE-FE0024233. Nonfederal funding was provided by the North Dakota Industrial Commission’s Oil and Gas Research Program and Computer Modelling Group.

04 OIL SHALES AND TAR SANDS↗

DOE OSTI2024

Reimagining Earth in the Earth System

Abstract Terrestrial, aquatic, and marine ecosystems regulate climate at local to global scales through exchanges of energy and matter with the atmosphere and assist with climate change mitigation through nature‐based climate solutions. Climate science is no longer a study of the physics of the atmosphere and oceans, but also the ecology of the biosphere. This is the promise of Earth system science: to transcend academic disciplines to enable study of the interacting physics, chemistry, and biology of the planet. However, long‐standing tension in protecting, restoring, and managing forest ecosystems to purposely improve climate evidences the difficulties of interdisciplinary science. For four centuries, forest management for climate betterment was argued, legislated, and ultimately dismissed, when nineteenth century atmospheric scientists narrowly defined climate science to the exclusion of ecology. Today's Earth system science, with its roots in global models of climate, unfolds in similar ways to the past. With Earth system models, geoscientists are again defining the ecology of the Earth system. Here we reframe Earth system science so that the biosphere and its ecology are equally integrated with the fluid Earth to enable Earth system prediction for planetary stewardship. Central to this is the need to overcome an intellectual heritage to the models that elevates geoscience and marginalizes ecology and local land knowledge. The call for kilometer‐scale atmospheric and ocean models, without concomitant scientific and computational investment in the land and biosphere, perpetuates the geophysical view of Earth and will not fully provide the comprehensive actionable information needed for a changing climate.

Meteorology & Atmospheric Sciences↗

DOE OSTI2025

Experimental investigation on phase change material–based finned tube heat exchanger for thermal energy storage and building envelope thermal management

Phase change materials (PCMs) are attractive solutions for thermal energy storage (TES) applications by absorbing and releasing large amounts of latent heat during solid–liquid phase transitions. However, their relatively low thermal conductivity requires novel heat exchanger–based solutions to improve the power density and overall energy storage efficiency of the TES system. This work presents the design and experimental results of a finned tube heat exchanger to store collected natural thermal energy from a building envelope in a latent-based TES and to release it later for building heating/cooling applications. We experimentally evaluate the finned tube heat exchanger and evaluate the performance of TES in reducing building heating and cooling loads over 3–4 h of desired time of operation (e.g., peak load). The optimized design allows for maximum energy density by minimizing the heat exchanger volume, and the system is evaluated experimentally using commercially available heat exchanger materials and an organic PCM. Here, the experimental results reveal that the TES system is able to charge and discharge stored latent energy within 3–4 h, matching peak building electricity demand duration under an average fluid flow rate of 0.136 kg/s and temperature difference of 5.55 °C. Importantly, such optimized designs illuminate a path toward TES designs that are low-cost, scalable, and optimized for thermal energy and power availability under the desired time of operation.

25 ENERGY STORAGE↗

DOE OSTI2022

A robust deep learning workflow to predict multiphase flow behavior during geological C O 2 sequestration injection and Post-Injection periods

Simulation of multiphase flow in porous media is essential to manage the geologic CO 2 sequestration (GCS) process, and physics-based simulation approaches usually take prohibitively high computational cost due to the nonlinearity of the coupled physics. This paper contributes to the development and evaluation of a deep learning workflow that accurately and efficiently predicts the temporal-spatial evolution of pressure and CO 2 plumes during injection and post-injection periods of GCS operations. Based on a Fourier Neural Operator, the deep learning workflow takes input variables or features including rock properties, well operational controls and time steps, and predicts the state variables of pressure and CO 2 saturation. To further improve the predictive fidelity, separate deep learning models are trained for CO 2 injection and post-injection periods due to the difference in primary driving force of fluid flow and transport during these two phases. We also explore different combinations of features to predict the state variables. We use a realistic example of CO 2 injection and storage in a 3D heterogeneous saline aquifer, and apply the deep learning workflow that is trained from physics-based simulation data and emulate the physics process. Through this numerical experiment, we demonstrate that using two separate deep learning models to distinguish post-injection from injection period generates the most accurate prediction of pressure, and a single deep learning model of the whole GCS process including the cumulative injection volume of CO 2 as a deep learning feature, leads to the most accurate prediction of CO 2 saturation. For the post-injection period, it is key to use cumulative CO 2 injection volume to inform the deep learning models about the total carbon storage when predicting either pressure or saturation. The deep learning workflow not only provides high predictive fidelity across temporal and spatial scales, but also offers a speedup of 250 times compared to full physics reservoir simulation, and thus will be a significant predictive tool for engineers to manage the long-term process of GCS.

58 GEOSCIENCES↗

DOE OSTI2023

Modeling of Chemical Slurry Rheology in DWPF Sludge Batch (SB) 10 Simulants

The Defense Waste Processing Facility (DWPF) treats high-activity radionuclides from sludge through a process called vitrification. This process converts radioactive liquid waste currently stored in tank farms into a solid glass form that is suitable for long-term storage and disposal. Due to the complexities involved in vitrifying this waste within each operation of the Chemical Processing Cell (CPC), waste rheology is studied to characterize the fluid-mechanical properties as it passes through the CPC and into the Melter. To better understand the waste and validate flow behavior, slurry rheology of simulants that represents the waste was studied at various acid stoichiometry percentages and solids concentrations to determine the simulant’s yield stress and viscosity. This research work has been supported by the DOE-FIU Science & Technology Workforce Development Initiative, an innovative program developed by the U.S. Department of Energy’s Office of Environmental Management (DOE-EM) and Florida International University’s Applied Research Center (FIU-ARC). During the spring of 2022, a DOE Fellow intern, Brendon Cintas, spent 10 weeks doing a summer internship at Savannah River National Laboratory (SRS) under the supervision and guidance of Dan Lambert, Chemical Flowsheet Development. The intern’s project was initiated on June 6, 2022, and continued through August 11, 2022 with the objective of assisting scientists at SRNL’s Rheology and Grout Laboratory at Aiken Country Technology Lab (ACTL) better understand the sludge composition on the rheology of a simulant slurry using a HAAKE RheoStress 6000 rheometer and extrapolate the results to the real-waste data.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2020

Experimental Analysis of Salt Hydrate Latent Heat Thermal Energy Storage System With Porous Aluminum Fabric and Salt Hydrate as Phase Change Material With Enhanced Stability and Supercooling

Phase change materials (PCMs), especially salt hydrates possess high volumetric energy storage capacity in their transition temperature range. These materials are used in applications where it is necessary to store thermal energy due to temporary load shift between demand and availability. Thus, possible applications are HVAC, recovery of waste heat, and defense thermal management. Despite salt hydrates potential, the practical feasibility of latent heat storage with salt hydrates is limited due to low power rating, supercooling, phase segregation, and long-term stability. Its low power rating and long-term stability limits its application in most applications. This work experimentally validates the stability and thermal performance of a compact heat exchanger charged with salt hydrate during melting and freezing. The compact heat exchanger was designed with fins on both the heat transfer fluid (HTF) and salt hydrate PCM side. The thermal performance of the latent heat thermal energy storage system (LHTESS) was evaluated for various operating conditions. The results show that LHTESS could achieve an average heat transfer coefficient of 124 and 87 W/(m2 K) during melting and solidification, respectively. The stability of the system in suppressing supercooling was validated over 800 cycles with nucleating agent and active homogenous nucleation techniques. The supercooling was reduced to 3 °C with zinc hydroxyl nitrate as nucleating agent and less than 1 °C with the active homogenous nucleation technique. The LHTESS showed less than 6% degradation in energy storage capacity over 800 cycles.

42 ENGINEERING↗

DOE OSTI2024

Workflow for Developing and Operating Subsurface Hydrogen Storage Facilities in Porous Reservoirs

Long-duration (seasonal) storage of natural gas (NG), which primarily consists of methane (CH 4 ), has been practiced for more than a hundred years at underground gas storage (UGS) facilities that use depleted hydrocarbon reservoirs, saline aquifers, and salt caverns. To enable hydrogen (H 2 ) to be used as a long-duration, energy-storage medium, similar facilities are envisioned for underground H 2 storage (UHS) of either H 2 or H 2 /NG mixtures. Experience with UGS can be used to guide recommended practices for developing and operating UHS facilities in porous reservoirs. The most important factors (formation/fluid properties and engineering choices) that influence the performance of UHS reservoirs have been identified and quantified in previous studies. These factors and choices influence phenomena that determine the sweep efficiency of the stored working gas. These phenomena include viscous fingering, hysteretic capillary trapping, and gravity override of the working gas, as well as the upconing of nonproductive fluid that determine the sweep efficiency of the stored working gas. This report describes initial recommended-practices and a project-development workflow for UHS facilities that utilize porous reservoirs, based on the current state-of-knowledge about H 2 behavior in the subsurface. The workflow sequentially addresses all aspects of UHS project development, including the identification of H 2 sources and users, site ranking and down-selection, geologic and reservoir-engineering characterization, reservoir design, testing, risk management, commissioning, operations, and monitoring for a UHS facility. The goal is to enable UHS facilities to be developed in an efficient and timely manner, while carefully managing project risks. This workflow is similar to that which has been developed for UGS facilities (see Figure 1 of API, 2022), with the addition of tasks and subtasks specific to H 2 and UHS. The project-development workflow is broken down into three major stages: (1) define the H 2 use case; (2) rank, down-select, and characterize potential, candidate UHS sites; and (3) reservoir design, integrity testing, risk assessment, commissioning, operations, and monitoring for selected UHS sites. Each major stage is further broken down into tasks and subtasks, which are described at a high level. This report also provides more detailed descriptions of all tasks and subtasks that involve reservoir analysis and testing.

08 HYDROGEN↗

DOE OSTI2022

Geothermal Fault Zone and Fluid Imaging through Joint Airborne ZTEM and Ground MT Data Inversion Analysis

This project has aimed to achieve detailed electrical resistivity resolution at geothermal reservoir scales by combining airborne natural electromagnetic (EM) field surveying (ZTEM) with ground magnetotelluric (MT) measurements to approximate an airborne MT geophysical method. MT alone is relatively expensive and may have permitting challenges in sensitive areas. Airborne ZTEM field data contains only the magnetic field, requires a background assumption, and has been limited to relatively high frequencies, thus suffering uniqueness problems. Based on proto-type 2D simulations, ZTEM ambiguities may be reduced through formal incorporation with possibly sparse ground MT soundings, which we pursued in full 3D for this project. The methodology was tested at the high-temperature Roosevelt Hot Springs geothermal system, Utah, which was considered advantageous given the near total exposure of crystalline reservoir rocks across the project area. ZTEM and ground MT survey data were acquired in 2017, subcontracted to outside parties with which we have worked in the past. These included 80 remote-referenced tensor MT soundings over the Mineral Mountains and adjacent Roosevelt Hot Spring producing geothermal system. These MT stations abut later coverage of a similar number of MT stations taken for the Utah FORGE project providing excellent total data aperture to re-solve structure beneath both project areas better than either set alone. The airborne ZTEM survey covered 704 line kilometers in E-W flight lines with a 250 m line spacing. Although this survey was timed during a maintenance-related shutdown of power production at the Roosevelt Hot Springs, other noise sources difficult to identify but including two high-voltage state-scale transmission lines compromised the ZTEM survey badly leading to unusable responses. Thus, with DOE management concurrence, the project proceeded to emphasize inversion and interpretation of the joint SubTER-FORGE MT data sets with regard to the Roosevelt Hot Springs reservoir recharge and to deep heat sources for both it and the Utah FORGE EGS project area. We also investigated the joint ZTEM-MT sampling concept with data sets from the Eleven Mile Canyon prospect area donated by the U.S. Navy (A. Sabin, PoC). Inversion of the SubTER-FORGE MT data using the HexMT 3D finite element algorithm reveals a large, low-resistivity anomaly extending sub-vertically through the depth range of the crust beneath the western Mineral Mountains. The steep conductive zone connects in the lower crust to a more tabular conductor characteristic of much of the Great Basin that generally is ascribed to current mafic magmatic underplating, hybridization and fluid release. The location of the resolved anomaly relative to the recent (0.5-0.8 Ma) eruptive centers of the Mineral Mountains implicates it as remnants of the magma body which fed these centers. This structure appears to be currently feeding heat and fluids upward into the Roosevelt Hot Springs hydrothermal system, as well as heat laterally to the FORGE project area. Separate and joint inversion models were carried out for the donated Eleven Mile Canyon MT-ZTEM data set to demonstrate concept. ZTEM only inversion showed two main alteration zones in the western portion of the project area known from geological mapping. Joint inversion including an E-W profile of MT soundings sharpened these features considerably. It also resolved in much greater detail the graben related normal faulting structure of the central project area which lies at depths exceeding the sensitivity of ZTEM alone. The sparse number of MT da-ta relative to the ZTEM required upweighting the former by a factor of several, but an exact procedure awaits future research. Our final impression is that sparse MT data can improve resolution of the subsurface over that of ZTEM alone. However, well sampled MT data are to be preferred and offer the simplicity of interpreting just one data type, and possess the superior resolution capability coming with the electric field everywhere, and from their high bandwidth.

15 GEOTHERMAL ENERGY↗

DOE OSTI2019

Initial Simulations of Empty Room Collapse and Reconsolidation at the Waste Isolation Pilot Plant

The Waste Isolation Pilot Plant (WIPP) is a geologic repository for defense-related nuclear waste. If left undisturbed, the virtually impermeable rock salt surrounding the repository will isolate the nuclear waste from the biosphere. If humans accidentally intrude into the repository in the future, then the likelihood of a radionuclide release to the biosphere will depend significantly on the porosity and permeability of the repository itself. Room ceilings and walls at the WIPP tend to collapse over time, causing rubble piles to form on floors of empty rooms. The surrounding rock formation will gradually compact these rubble piles until they eventually become solid salt, but the length of time for a rubble pile to reach a certain porosity and permeability is unknown. This report details the first efforts to build models to predict the porosity and permeability evolution of an empty room as it closes. Conventional geomechanical numerical methods would struggle to model empty room collapse and rubble pile consolidation, so three different meshless methods, the Immersed Isogeometric Analysis Meshfree, Reproducing Kernel Particle Method (RKPM), and the Conformal Reproducing Kernel method, were assessed. First, the meshless methods and the finite element method each simulated gradual room closure, without ceiling or wall collapse. All three methods produced equivalent room closure predictions with comparable computational speed. Second, the Immersed Isogeometric Analysis Meshfree method and RKPM simulated two-dimensional empty room collapse and rubble pile consolidation. Both methods successfully simulated large viscoplastic deformations, fracture, and rubble pile rearrangement to produce qualitatively realistic results. In addition to geomechanical simulations, the flow channels in damaged salt and crushed salt were measured using micro-computed tomography, and input into a computational fluid dynamics simulation to predict the salt's permeability. Although room for improvement exists, the current simulation approaches appear promising.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗