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At least 271 records · Page 15

Assessment of the Griffin Reactor Multiphysics Application Using the Empire Micro Reactor Design Concept

In late 2019, INL and ANL agreed to jointly develop the reactor physics code named Griffin based on the integration of the two code suites, MAMMOTH/Rattlesnake (INL) and MC2 - 3/PROTEUS (ANL). Griffin is being developed based on the MOOSE framework and MOOSE quality assurance procedures. This decision was made to be able to allow DOE-NE to efficiently invest funding to this area and to provide effective and timely support for existing and potential users; the latter includes industry and government organizations who are developing various types of advanced reactors in the near and long term. Since MAMMOTH/Rattlesnake has been developed based on the MOOSE framework, the INL/ANL Griffin development team agreed to build Griffin beginning with a merger of MAMMOTH and Rattlesnake into a single code and moving forward by implementing capabilities from the PROTEUS suite into Griffin. Moving forward, both ANL and INL efforts are equally invested in the Griffin project, with management support, to provide an advanced reactor multiphysics tool to assist in reactor design, optimization, and safety analysis. Much work remains in moving Griffin forward to migrate PROTEUS capabilities and to optimize performance to meet user needs. The main objective of this work is to assess the current status of Griffin capabilities in terms of performance and accuracy, to determine priorities for PROTEUS migration, and to identify capabilities and features to improve for supporting the code integration effort. For this assessment, the Empire micro reactor problem that was developed in the ARPA-E MEITNER program was selected as an advance reactor concept of interest to the technical community. The Empire reactor problem was expanded from its original incomplete specification to be a small heat-pipe-cooled micro reactor core with ~113 cm radius and 70 cm in height, composed of 18 fuel assemblies, 12 control drums, and beryllium radial and axial reflectors. In the current model, using 5 cm axial reflectors specified in the original Empire assembly model, more than 10% of neutrons leak axially and through the empty center safety hole, as well as through heat pipe channels in fuel assembly elements that extend through the top reflector region. Several calculation models of the core were defined for systematic assessment, including 2-D and 3-D fuel assemblies and whole cores with cylindrical boundaries. Cross sections were generated using Serpent 2, and meshes were produced using the Argonne mesh tool or the INL neutronics meshing tools combined with CUBIT. Cross sections and meshes were converted to the ISOXML and Exodus formats, respectively, so that Griffin and PROTEUS could use consistent data for solving the reactor problems. With the prepared cross sections and meshes, PROTEUS was run first to ensure that all input data were correctly generated and input options in terms of angle, mesh, and energy group were accurately determined. Comparisons against Serpent 2 solutions were made in terms of eigenvalue and pin power. The same calculations and comparisons were then conducted using Griffin. For the fuel assembly and whole core problems, the PROTEUS eigenvalues agreed well with reference Serpent 2 solutions within 100 and 30 pcm, respectively, and pin power differences relative to Serpent 2 were overall less than 2.2% and RMS 0.8% for the whole core models. This indicated that all input data were properly prepared. Using the same data, Griffin was run selecting the SAAF-CFEM SN solver with Legendre-Gaussian quadrature and NDA and DSA for acceleration. It was found that the SAAF-CFEM solver of Griffin required finer meshes to achieve eigenvalue and pin power solutions in good agreement with Serpent 2, consequently requiring more memory requirement and longer computation time. On the other hand, the SPH-Diffusion 2-D core calculations performed using Griffin were able to recover the exact eigenvalue from the reference Serpent 2 solutions, resulting in a pin-power distribution with an RMS of 0.6% and maximum absolute difference of less than 1.4%. The runtimes for SPH-Diffusion for the 2-D core were less than 3 minutes on 40 cores. During this evolution of this evaluation, many updates were made in Griffin by the Griffin development team of INL (focusing on software updates) and ANL (reviewing and supporting software updates) to complete this assessment. Observations from the code assessment are presented in the conclusion section of this report, followed by a discussion of recommendations for future work.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Design and development of a leak tight helium II valve with low thermal impact

The Lambda Point Experiment is a precision measurement of the specific heat of liquid helium near the lambda point phase transition, in the low gravity of the space shuttle. It requires a valve for the helium sample chamber that operates at helium II temperature, has minimal thermal disturbance to the rest of the instrument, and is leak tight to helium II. A valve meeting these and all of the other science and engineering requirements of the mission has been developed by Ball. Initially, both torque and pressure actuated valve concepts were considered; the final flight design is pressure actuated. The rational for this decision as well as the rest of the valve design are given. The paper also discusses the manufacturing and testing of the prototype and flight valves. Test data is presented and discussed.

Mills, G. L.↗

Shape-stabilized phase change materials for energy storage based on hierarchically porous calcium magnesium carbonate

A composite phase-change material containing a hierarchically porous Ca 1-x Mg x CO 3 and having pores loaded with a phase change material is described. The heat storage material has a latent heat of melting 123 to 221 J/g, a latent heat of freezing of 107 to 201 J/g, and a thermal conductivity of 0.22 to 0.45 W·m −1 ·K −1 . The phase change material may be polyethylene glycol, and the polyethylene glycol does not leak from the pores of the hierarchically porous Ca 1-x Mg x CO 3 when heating or cooling over phase transitions.

25 ENERGY STORAGE↗

Cryogenic Feedthrough Test Rig

The cryogenic feedthrough test rig (CFTR) allows testing of instrumentation feedthroughs at liquid oxygen and liquid hydrogen temperature and pressure extremes (dangerous process fluid) without actually exposing the feedthrough to a combustible or explosive process fluid. In addition, the helium used (inert gas), with cryogenic heat exchangers, exposes the feedthrough to that environment that allows definitive leak rates of feedthrough by typical industry-standard helium mass spectrometers.

Skaff, Antony↗

Thermal-Flow Code for Modeling Gas Dynamics and Heat Transfer in Space Shuttle Solid Rocket Motor Joints

A new, thermal-flow simulation code, called SFLOW. has been developed to model the gas dynamics, heat transfer, as well as O-ring and flow path erosion inside the space shuttle solid rocket motor joints by combining SINDA/Glo, a commercial thermal analyzer. and SHARPO, a general-purpose CFD code developed at Thiokol Propulsion. SHARP was modified so that friction, heat transfer, mass addition, as well as minor losses in one-dimensional flow can be taken into account. The pressure, temperature and velocity of the combustion gas in the leak paths are calculated in SHARP by solving the time-dependent Navier-Stokes equations while the heat conduction in the solid is modeled by SINDA/G. The two codes are coupled by the heat flux at the solid-gas interface. A few test cases are presented and the results from SFLOW agree very well with the exact solutions or experimental data. These cases include Fanno flow where friction is important, Rayleigh flow where heat transfer between gas and solid is important, flow with mass addition due to the erosion of the solid wall, a transient volume venting process, as well as some transient one-dimensional flows with analytical solutions. In addition, SFLOW is applied to model the RSRM nozzle joint 4 subscale hot-flow tests and the predicted pressures, temperatures (both gas and solid), and O-ring erosions agree well with the experimental data. It was also found that the heat transfer between gas and solid has a major effect on the pressures and temperatures of the fill bottles in the RSRM nozzle joint 4 configuration No. 8 test.

Wang, Qunzhen↗

Advanced Serpentine Heat Exchangers to Minimize Number of Joints and Leakage in HVAC&R Systems

Refrigerant leakage has a significant impact on heating, ventilation, air conditioning and refrigeration (HVAC&R) industries in terms of both greenhouse gas (GHG) emissions and lost efficiency of the systems themselves. One of the major causes of refrigerant leakage is braze joints within a vapor compression system. The brazing process is often inconsistent and almost always imperfect. As a result, braze joints are left vulnerable to leaks and can be weaker than non-brazed tubing. Conventional tube-fin heat exchangers are manufactured using one brazed joint per tube. An alternative to the conventional approach is the use of a single continuous serpentine tube. An Advanced Serpentine Heat Exchanger was developed to provide a heat transfer solution that meets or exceeds performance while also significantly reducing the number of joints and, consequently, the potential for refrigerant leakage. The developed serpentine heat exchanger not only delivers on performance, but is also cost competitive with conventional heat exchangers on the market.

30 DIRECT ENERGY CONVERSION↗

A high-performance lung-inspired ceramic 3D-printed heat exchanger for high-temperature energy-efficient systems

The thermal-to-electric conversion efficiency of next-generation supercritical carbon dioxide and concentrated solar power plants is significantly augmented by operating at temperatures exceeding 1000 °C if durable, compact, high-temperature heat exchangers (HXs) are developed. Whereas metal 3D-printed HXs fail to operate under extreme temperature conditions, ceramic 3D-printed HXs are deemed promising candidates for high-temperature, highly oxidizing environments. Ceramic 3D-printed HXs, however, exhibit a high gas permeability issue through hot and cold separating walls due to an excessive non-volatile photopolymer content utilized. Here, in this work, a novel leak-free lung-inspired ceramic 3D-printed HX employing a highly complex heat transfer topology is introduced for high-temperature energy-efficient systems. The high permeability issue of ceramic 3D-printed HXs is fully eliminated through a uniform zinc-based coating. It was determined that the effective thermal conductivity of the sintered ceramic heat exchangers is affected by the coated layer. The high-temperature thermal and hydraulic characteristics of the lung-inspired ceramic 3D-printed HX are comprehensively examined and compared against a millichannel 3D-printed HX module. Experimental results indicated that the lung-inspired 3D-printed ceramic HX significantly outperforms its millichannel counterpart. The lung-inspired HX shows a volume-based power density of 8.2 MW/m3 at a hot-side inlet air temperature of 700°C, a 71 % improvement compared with that of the millichannel HX. More importantly, the higher thermal duty of the lung-inspired 3D-printed HX is realized at a lower normalized pressure drop penalty of 510 Pa/W, 22 % lower than that of the millichannel ceramic HX. This study accelerates the advancement of high-performance ceramic 3D-printed HXs with complex topologies for high-temperature energy-efficient systems and/or corrosive environments.

42 ENGINEERING↗

Pressure and heat-transfer distributions in a simulated wing-elevon cove with variable leakage at a free-stream Mach number of 6.9

A concern that ingestion of hot boundary-layer gas past a small, localized seal failure in the cove between the Space Shuttle wing and elevon might threaten unprotected elevon structures led to wind-tunnel tests to define cove environment as a function of leak area. The tests were conducted in the Langley 8-foot high-temperatures structures tunnel using a full-scale representation of the Space Shuttle wing-elevon juncture on the reentry surface. Pressure and heating rates were obtained for both attached and separated turbulent flows on the wing at the cove entrance. Results indicated that (1) for attached turbulent flow on the wing, cove heating progressively increased in severity independent of leak aspect ratio as leak area increased to 100 percent of cove entrance area and (2), for separated turbulent flow over the wing, cove environment was intolerably severe.

Deveikis, W. D.↗

Evaluation of the Energy, Hygrothermal, and Thermal Capacity Performance of Cross-Laminated Timber

Cross-laminated timber (CLT) construction is gaining momentum in the US because it offers multiple advantages over traditional construction methods. Benefits that have received the most attention focus on constructability, the environment, and protection (e.g., blast resistance), although CLT construction is likely to offer other benefits, as well. Still, these have not been studied at length because such evaluations are costly, requiring long-term assessments in an actual building and specialized technical knowledge. Among the possible benefits, CLT construction likely provides a higher-performing building envelope. Using CLT panels to enclose a building means fewer joints in the opaque envelope than what is required in traditional stick-framed construction. Fewer joints mean fewer locations where the air- and water-resistive barrier (WRB) could be compromised; thus, a CLT building enclosure may require less maintenance and have a longer lifespan than a traditionally built structure because of fewer air and water leaks. In addition, CLT’s thermal mass moderates indoor temperatures, allowing the heating, ventilation, and air conditioning (HVAC) system to operate more efficiently during peak hours, reducing operational energy consumption throughout the lifetime of the CLT building (Salonvaara et al., 2022). Furthermore, more stable indoor temperatures can increase occupant comfort. The CLT’s thermal mass can also reduce energy costs by adjusting to utility time-of-use pricing without affecting occupant comfort. The ability of CLT buildings to bridge periods without HVAC operation prepares them for future grid interaction and provides a certain level of resilience against power outages. Researchers have attempted to quantify these benefits; however, their work is based on simplified simulations with numerous assumptions. To correctly understand the benefits, an actual building must be monitored. Therefore, information needs to be gathered on indoor and outdoor temperatures, HVAC energy consumption, thermostat setpoints, temperatures, and thermal transport in CLT components to comprehend how these parameters are affected by the CLT’s thermal mass. These data are needed to reduce the number of assumptions and calibrate simulation models to optimize HVAC controls to minimize overall energy consumption, reduce energy use and higher fees during peak demand, and maintain occupant comfort. Additionally, the calibrated simulation model allows the optimization exercise to be repeated in various US climates. Potential benefits can be tailored to buildings in various locations, and decisions can be made on where CLT construction could be most advantageous. Furthermore, monitoring and simulation results are needed to evaluate the durability of the CLT structures in different climates. This project’s researchers gathered information to help understand and quantify the benefits of CLT buildings concerning operational energy, moderated indoor temperatures, and comfort; the dynamic operation to provide grid services; and resilience in times of power outage. Through the corroboration of simulation models with real-world measurements, this study paves the way for extrapolating findings to other climatic zones and building typologies, thereby broadening the understanding of CLT’s multifaceted benefits and reinforcing its position as a material of choice in sustainable construction.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Designing a Composable Geometric Toolkit for Versatility in Applications to Simulation Development

Conceived and implemented through the development of probabilistic risk assessment simulations for Project Constellation, the Geometric Toolkit allows users to create, analyze, and visualize relationships between geometric shapes in three-space using the MATLAB computing environment. The key output of the toolkit is an analysis of how emanations from one "source" geometry (e.g., a leak in a pipe) will affect another "target" geometry (e.g., another heat-sensitive component). It can import computer-aided design (CAD) depictions of a system to be analyzed, allowing the user to reliably and easily represent components within the design and determine the relationships between them, ultimately supporting more technical or physics-based simulations that use the toolkit. We opted to develop a variety of modular, interconnecting software tools to extend the scope of the toolkit, providing the capability to support a range of applications. This concept of simulation composability allows specially-developed tools to be reused by assembling them in various combinations. As a result, the concepts described here and implemented in this toolkit have a wide range of applications outside the domain of risk assessment. To that end, the Geometric Toolkit has been evaluated for use in other unrelated applications due to the advantages provided by its underlying design.

Reed, Gregory S.↗

Testing the Shuttle heat-protection armor

The article deals with the thermal protection system (TPS) designed to keep Space Shuttle structures at 350 F ratings over a wide range of temperatures encountered in orbit, but also during prelaunch, launch, deorbit and re-entry, landing and turnaround. The structure, function, fabrication, and bonding of various types of reusable surface insulation and composite materials are described. Test programs are developed for insulation, seals, and adhesion bonds; leak tests and acoustic fatigue tests are mentioned. Test facilities include arc jets, radiant heaters, furnaces, and heated tunnels. The certification tests to demonstrate TPS reusability, structural integrity, thermal performance, and endurance will include full-scale assembly tests and initial orbital flight tests.

Strouhal, G.↗

Slotting Fins of Heat Exchangers to Provide Thermal Breaks

Heat exchangers that include slotted fins (in contradistinction to continuous fins) have been invented. The slotting of the fins provides thermal breaks that reduce thermal conduction along flow paths (longitudinal thermal conduction), which reduces heat-transfer efficiency. By increasing the ratio between transverse thermal conduction (the desired heat-transfer conduction) and longitudinal thermal conduction, slotting of the fins can be exploited to (1) increase heat-transfer efficiency (thereby reducing operating cost) for a given heat-exchanger length or to (2) reduce the length (thereby reducing the weight and/or cost) of the heat exchanger needed to obtain a given heat transfer efficiency. By reducing the length of a heat exchanger, one can reduce the pressure drop associated with the flow through it. In a case in which slotting enables the use of fins with thermal conductivity greater than could otherwise be tolerated on the basis of longitudinal thermal conduction, one can exploit the conductivity to make the fins longer (in the transverse direction) than they otherwise could be, thereby making it possible to make a heat exchanger that contains fewer channels and therefore, that weighs less, contains fewer potential leak paths, and can be constructed from fewer parts and, hence, reduced cost.

Scull, Timothy D.↗

Design of the Brine Evaporation Bag for Increased Water Recovery in Microgravity

The existing water recovery system on the International Space Station (ISS) is limited to 75% reclamation; consequently, long duration space missions are currently unfeasible due to the large quantity of water necessary to sustain the crew. The Brine Evaporation Bag (BEB) is a proposed system to supplement the existing water recovery system aboard the ISS that can to increase water recovery to 99%. The largest barrier to high water recovery is mineral scaling inside the water recovery equipment, which leads to equipment failure; therefore, some water must remain to keep the minerals dissolved. This waste stream is liquid brine containing salts, acids, organics, and water. The BEB is designed to recover this remaining water while protecting the equipment from scale. The BEB consists of a sealed bag containing a hydrophobic membrane that allows water vapor and gas to pass through. It is operated under vacuum, heated, and continuously filled with brine to boil away the water. The water vapor is recovered and the solids are contained inside the bag for disposal. The BEB can dry the brine to a solid block. Ongoing work includes improving the design of the BEB and the evaporator to prevent leaks, maximize the rate of water removal, and minimize energy use and weight. Additional testing will determine whether designs are heat- or mass-transfer limited and the optimal water recovery rate.

Brine Evaporation Bag↗

Spinoff 2012

Topics covered include: Water Treatment Technologies Inspire Healthy Beverages; Dietary Formulas Fortify Antioxidant Supplements; Rovers Pave the Way for Hospital Robots; Dry Electrodes Facilitate Remote Health Monitoring; Telescope Innovations Improve Speed, Accuracy of Eye Surgery; Superconductors Enable Lower Cost MRI Systems; Anti-Icing Formulas Prevent Train Delays; Shuttle Repair Tools Automate Vehicle Maintenance; Pressure-Sensitive Paints Advance Rotorcraft Design Testing; Speech Recognition Interfaces Improve Flight Safety; Polymers Advance Heat Management Materials for Vehicles; Wireless Sensors Pinpoint Rotorcraft Troubles; Ultrasonic Detectors Safely Identify Dangerous, Costly Leaks; Detectors Ensure Function, Safety of Aircraft Wiring; Emergency Systems Save Tens of Thousands of Lives; Oxygen Assessments Ensure Safer Medical Devices; Collaborative Platforms Aid Emergency Decision Making; Space-Inspired Trailers Encourage Exploration on Earth; Ultra-Thin Coatings Beautify Art; Spacesuit Materials Add Comfort to Undergarments; Gigapixel Images Connect Sports Teams with Fans; Satellite Maps Deliver More Realistic Gaming; Elemental Scanning Devices Authenticate Works of Art; Microradiometers Reveal Ocean Health, Climate Change; Sensors Enable Plants to Text Message Farmers; Efficient Cells Cut the Cost of Solar Power; Shuttle Topography Data Inform Solar Power Analysis; Photocatalytic Solutions Create Self-Cleaning Surfaces; Concentrators Enhance Solar Power Systems; Innovative Coatings Potentially Lower Facility Maintenance Costs; Simulation Packages Expand Aircraft Design Options; Web Solutions Inspire Cloud Computing Software; Behavior Prediction Tools Strengthen Nanoelectronics; Power Converters Secure Electronics in Harsh Environments; Diagnostics Tools Identify Faults Prior to Failure; Archiving Innovations Preserve Essential Historical Records; Meter Designs Reduce Operation Costs for Industry; Commercial Platforms Allow Affordable Space Research; Fiber Optics Deliver Real-Time Structural Monitoring; Camera Systems Rapidly Scan Large Structures; Terahertz Lasers Reveal Information for 3D Images; Thin Films Protect Electronics from Heat and Radiation; Interferometers Sharpen Measurements for Better Telescopes; and Vision Systems Illuminate Industrial Processes.

Source record↗

High-Differential-Pressure Heat Exchanger

Heat exchanger accommodates large pressure difference between heat-transfer fluids. Designed so all welded joints inspected with x rays to ensure leak-free operation over many years. Joints between fluids and between each fluid and environment radiographically inspectable. Used in Stirling-cycle engines, including those in proposed nuclear and solar powerplants.

Hylin, Edward C.↗

Fused filament fabrication of novel phase-change material functional composites

Additively manufactured polymer heat exchangers are of recent interest in the thermal sciences due to their lightweight and intricate heat-transfer-enhancing geometrical features. The goal of the present research is to directly encapsulate phase-change material (PCM) into polymer filament for the purpose of 3D printing polymer heat exchangers capable of latent heat thermal energy storage and management. PCMs have the ability to absorb large amounts of latent heat while undergoing a solid-to-liquid phase change at a nearly constant temperature. Encapsulation or containment of PCMs is necessary to prevent leaking since the material continuously cycles between a liquid and a solid state. An organic-based PCM and high-density polyethylene (HDPE) were combined and extruded into a functional composite filament. For the first time, with the aid of a heated enclosure and HDPE build plates, it was demonstrated that these functional composite materials can be printed using fused filament fabrication (FFF). Printing HDPE is known to be difficult; however, based on what was observed in the current study, the PCM and HDPE composite was easier to print than pure HDPE. Thermal properties, such as latent heat of fusion, phase-change temperature, and thermal conductivity, of the composite filament and 3D printed samples were investigated and compared with compression-molded bulk material. Finally, the microstructures of the composite filament and 3D printed samples were visualized, and the basic structures of the HDPE and PCM within both the filament and 3D printed parts were clearly delineated.

36 MATERIALS SCIENCE↗

Modeling Efforts to Gain Insight into Historical Leak Events from the Single-Shell Tank A-105 in the Hanford 241-A Tank Farm - 20113

The 241-A Tank Farm is a single-shell tank (SST) farm constructed to store process waste from Hanford nuclear operations. Millions of gallons of nuclear waste were stored in the 241-A Tank Farm SSTs and some of the SSTs leaked in the past. In addition, spills and pipeline leaks during transfers and storage and intentional discharges to cribs and trenches resulted in releasing waste to the ground. Tank liner leaks are referred to as 'leaks' and all other discharges to the soil are referred to as 'releases.' Liquid waste that could be removed by pumping has been removed from all of the SSTs to reduce the potential for future leaks. The most significant historical leak event in 241-A Tank Farm occurred in 1965 when tank A-105 experienced a pressurized steam event. This event resulted in damage to the inner steel liner flooring of A-105, which was separated from the sidewalls over part of its circumference and buckled up to 2.5 m, vertically. During this event up to 7,570 L of contaminated liquid may have leaked to the adjacent soil. This leak occurred under extreme temperature and pressure conditions. Modeling efforts to better understand the nature and extent of historical leaks from subsurface SSTs that were used to store highly radioactive, self-boiling liquid wastes at 241-A Tank Farm have recently been undertaken. These efforts have compiled the available historical information to support a preliminary non-isothermal, multiphase flow and chemical transport modeling effort to re-create the conditions under which the leaks occurred and to formulate a conceptual model as to the extent and distribution of leaked radioactive contaminants in the adjacent soil material. The focus of this work was on developing an understanding of the key features, processes and bounding conditions related to tank A-105 leak events that occurred in the 1960's. The activities include estimation of leak composition, non-isothermal multiphase flow and transport modeling, and geochemical modeling. The STOMP{sup C} Water-Air-Energy modeling code was utilized to implement the three-dimensional representation of the subsurface tank and the surrounding flow field. Once constructed, the model was used to evaluate the conceptual understanding of leaks originating from different parts of the tank under the elevated temperature boundary conditions that were imposed by surrounding tanks at the time of the historical leaks. The chemical evolution of the liquid waste was also evaluated as it leaked from the tank under transient pressure and temperature gradients. The results of the preliminary evaluation suggested the presence of a heat-pipe effect beneath tank A-105 in which water vapor at an elevated temperature is driven away from the base of the tank to a position where water vapor cools, condenses and is then drawn back toward the tank by the strong capillary attraction of the dry soil. A non-sorbing contaminant (Tc-99) was introduced into this flow field to better understand the potential distribution patterns of leaked contaminants that may have occurred during the historical leak events. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗