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At least 271 records · Page 15

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DOE OSTI2015

Pore-scale investigation on stress-dependent characteristics of granular packs and the impact of pore deformation on fluid distribution

Understanding the effect of changing stress conditions on multiphase flow in porous media is of fundamental importance for many subsurface activities including enhanced oil recovery, water drawdown from aquifers, soil confinement, and geologic carbon storage. Geomechanical properties of complex porous systems are dynamically linked to flow conditions, but their feedback relationship is often oversimplified due to the difficulty of representing pore-scale stress deformation and multiphase flow characteristics in high fidelity. In this work, we performed pore-scale experiments of single- and multiphase flow through bead packs at different confining pressure conditions to elucidate compaction-dependent characteristics of granular packs and their impact on fluid flow. A series of drainage and imbibition cycles were conducted on a water-wet, soda-lime glass bead pack under varying confining stress conditions. Simultaneously, X-ray micro-CT was used to visualize and quantify the degree of deformation and fluid distribution corresponding with each stress condition and injection cycle. Micro-CT images were segmented using a gradient-based method to identify fluids (e.g., oil and water), and solid phase redistribution throughout the different experimental stages. Changes in porosity, tortuosity, and specific surface area were quantified as a function of applied confining pressure. Results demonstrate varying degrees of sensitivity of these properties to confining pressure, which suggests that caution must be taken when considering scalability of these properties for practical modeling purposes. Changes in capillary number with confining pressure are attributed to the increase in pore velocity as a result of pore contraction. Furthermore, this increase in pore velocity was found to have a marginal impact on average phase trapping at different confining pressures.

58 GEOSCIENCES↗

DOE OSTI2018

Numerical Simulation of Multiphase Magnetohydrodynamic Flow and Deformation of Electrolyte–Metal Interface in Aluminum Electrolysis Cells

A computational fluid dynamics based multiphase magnetohydrodynamic (MHD) flow model for simulating the melt flow and bath–metal interface deformation in realistic aluminum reduction cells is presented. The model accounts for the complex physics of the MHD problem in aluminum reduction cells by coupling two immiscible fluids, electromagnetic field, Lorentz force, flow turbulence, and complex cell geometry with large length scale. Especially, the deformation of bath–metal interface is tracked directly in the simulation, and the condition of constant anode–cathode distance (ACD) is maintained by moving anode bottom dynamically with the deforming bath–metal interface. The metal pad deformation and melt flow predicted by the current model are compared to the predictions using a simplified model where the bath–metal interface is assumed flat. The effects of the induced electric current due to fluid flow and the magnetic field due to the interior cell current on the metal pad deformation and melt flow are investigated. The presented model extends the conventional simplified box model by including detailed cell geometry such as the ledge profile and all channels (side, central, and cross-channels). The simulations show the model sensitivity to different side ledge profiles and the cross-channel width by comparing the predicted melt flow and metal pad heaving. In addition, the model dependencies upon the reduction cell operation conditions such as ACD, current distribution on cathode surface and open/closed channel top, are discussed.

42 ENGINEERING↗

DOE OSTI2017

Development of a Reduced-Order Model for Reacting Gas-Solids Flow using Proper Orthogonal Decomposition

This report summarizes the objectives, tasks and accomplishments made during the three year duration of this research project. The report presents the results obtained by applying advanced computational techniques to develop reduced-order models (ROMs) in the case of reacting multiphase flows based on high fidelity numerical simulation of gas-solids flow structures in risers and vertical columns obtained by the Multiphase Flow with Interphase eXchanges (MFIX) software. The research includes a numerical investigation of reacting and non-reacting gas-solids flow systems and computational analysis that will involve model development to accelerate the scale-up process for the design of fluidization systems by providing accurate solutions that match the full-scale models. The computational work contributes to the development of a methodology for obtaining ROMs that is applicable to the system of gas-solid flows. Finally, the validity of the developed ROMs is evaluated by comparing the results against those obtained using the MFIX code. Additionally, the robustness of existing POD-based ROMs for multiphase flows is improved by avoiding non-physical solutions of the gas void fraction and ensuring that the reduced kinetics models used for reactive flows in fluidized beds are thermodynamically consistent.

42 ENGINEERING↗

DOE OSTI2014

CFD modeling of multiphase reacting flow in blast furnace shaft with layered burden

The ironmaking blast furnace is a counter-current chemical reactor which includes the ascending gas flow and the counter-current descending porous bed (burden). A Computational Fluid Dynamics (CFD) model has been developed to simulate the multiphase reacting flow in blast furnace shaft. The gas flow dynamics, burden movement, chemical reactions, heat and mass transfer between the gas phase and burden phase are included in the CFD model. The blast furnace burden consists of alternative layers of iron ore and coke. We propose a novel methodology in order to efficiently model the effects of alternative burden layer structure on gas flow, heat transfer, mass transfer and chemical reactions. Different reactions and heat transfer characteristics are applied for difference types of layer. In addition, the layered CFD model accurately predicts the Cohesive Zone (CZ) shape where the melting of solid burden taking place. Furthermore, we determine the shape and location of the CZ by an iterative method based on the ore temperature distribution. The theoretical formation and the methodology of the CFD model are presented and the model is applied to simulate industry blast furnaces. Finally, the proposed method can be applied to investigate the blast furnace shaft process and other moving bed system with periodic burden structure configuration.

42 ENGINEERING↗

DOE OSTI2016

A separate phase drag model and a surrogate approximation for simulation of the steam assisted gravity drainage (SAGD) process

General ensemble phase averaged equations for multiphase flows have been specialized for the simulation of the steam assisted gravity drainage (SAGD) process. In the average momentum equation, fluid-solid and fluid-fluid viscous interactions are represented by separate force terms. This equation has a form similar to that of Darcy’s law for multiphase flow but augmented by the fluid-fluid viscous forces. Models for these fluid-fluid interactions are suggested and implemented into the numerical code CartaBlanca. Numerical results indicate that the model captures the main features of the multiphase flow in the SAGD process, but the detailed features, such as plumes are missed. We find that viscous coupling among the fluid phases is important. Advection time scales for the different fluids differ by several orders of magnitude because of vast viscosity differences. Numerically resolving all of these time scales is time consuming. To address this problem, we introduce a steam surrogate approximation to increase the steam advection time scale, while keeping the mass and energy fluxes well approximated. This approximation leads to about a 40-fold speed-up in execution speed of the numerical calculations at the cost of a few percent error in the relevant quantities.

02 PETROLEUM↗

DOE OSTI2024

Modeling gas migration through clay-based buffer material using coupled multiphase fluid flow and geomechanics with stress-dependent gas permeability

A model for gas migration through clay-based buffer material is developed for modeling gas generation and migration associated with deep geologic nuclear waste disposal. The model is based on a multiphase fluid flow and geomechanics simulator that is adapted to consider enhanced gas flow when gas pressure is high enough to approach the confining stress magnitude. A key feature in the model is a direct coupling between gas permeability and stress, through a non-linear stress-dependent permeability function. The model was first tested and calibrated by modelling two different laboratory gas migration tests on Wyoming (MX-80) bentonite samples. The calibrated model was then applied to model gas migration through a bentonite buffer of a large-scale gas injection test (Lasgit) conducted at the Äspö Hard Rock Laboratory in Sweden. Observed preferential gas migration along interfaces (between compacted blocks and along the canister surface) required explicit representation of such interfaces in the model. The model with the stress-dependent gas permeability accurately captured observed experimental responses in terms of gas breakthrough time, peak gas pressure, and cumulative gas flow rates. The calibrated model was finally applied to simulate migration of hydrogen gas generated within a breached nuclear waste canister over 10,000 years, involving migration of much larger gas volumes. For the considered gas generation rate and host rock properties, the generated gas could migrate through the bentonite buffer and released into the surrounding host rock at a maximum gas pressure somewhat higher than the initial total stress, though a significant amount of hydrogen remained within the buffer. This modelling sets the stage for further detailed analysis of the impact of hydrogen gas generation on the long-term performance of nuclear waste repositories.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2018

Mathematical Investigation of Fluid Flow, Mass Transfer, and Slag-steel Interfacial Behavior in Gas-stirred Ladles

In this study, the Euler-Euler and Euler-Lagrange modeling approaches were applied to simulate the multiphase flow in the water model and gas-stirred ladle systems. Detailed comparisons of the computational and experimental results were performed to establish which approach is more accurate for predicting the gas-liquid multiphase flow phenomena. It was demonstrated that the Euler-Lagrange approach is more accurate than the Euler-Euler approach. The Euler-Lagrange approach was applied to study the effects of the free surface setup, injected bubble size, gas flow rate, and slag layer thickness on the slag-steel interaction and mass transfer behavior. Detailed discussions on the flat/non-flat free surface assumption were provided. Significant inaccuracies in the prediction of the surface fluid flow characteristics were found when the flat free surface was assumed. The variations in the main controlling parameters (bubble size, gas flow rate, and slag layer thickness) and their potential impact on the multiphase fluid flow and mass transfer characteristics (turbulent intensity, mass transfer rate, slag-steel interfacial area, flow patterns, etc.,) in gas-stirred ladles were quantitatively determined to ensure the proper increase in the ladle refining efficiency. It was revealed that by injecting finer bubbles as well as by properly increasing the gas flow rate and the slag layer thickness, the ladle refining efficiency can be enhanced significantly.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Development and validation of the cavitation-induced erosion risk assessment tool

This work presents the development of a cavitation-induced erosion risk assessment (CIERA) tool that links multiphase flow simulation predictions with the progress towards material erosion. To develop a robust erosion modeling tool, the cavitation and erosion predictions for pressurized diesel fuel flow within a channel geometry were validated over a range of Reynolds and cavitation number conditions in two different aluminum channel geometries, one featuring a rounded inlet corner and the other with a sharp inlet corner. The multiphase flow development within the channel was modeled using a compressible mixture model, where phase change was represented with the homogeneous relaxation model and the turbulent flow evolution was modeled using a dynamic structure approach for Large Eddy Simulations. To improve representation of the incubation period before material rupture over existing approaches, a physics-based metric was derived based on the cumulative energy absorbed by the solid material from repeated hydrodynamic impacts. When the average peak pressure was related to the incubation period, the incubation period and its sensitivity to changes in flow conditions were found to be overpredicted. In contrast, predictions from CIERA provided a more accurate means to qualitatively and quantitatively predict the influence of flow conditions on the incubation period before material erosion. When the predicted stored energy was related to the solid material properties to estimate the incubation period, multiphase flow simulations demonstrated accurate representation of the sensitivity of erosion severity to changes in flow conditions. The use of CIERA led to quantitative agreement of the predicted incubation period within 5% of the experimentally measured incubation period.

42 ENGINEERING↗

DOE OSTI2020

X-ray Computed Tomography on UNESE Core: FY2020 Data Report to Support Fracture and Multiphase Fluid Flow Studies

Natural and induced fractures are potential preferential pathways for migration of radioactive gases to earths surface from underground nuclear explosions (UNEs). This report documents X-ray computed tomography (XRCT) imaging on 26 samples of rock core that was collected to support the Underground Nuclear Explosion Signatures Experiment (UNESE) program. The XRCT datasets are intended to help fill a data gap on the three-dimensional (3D) characteristics of natural and/or induced fractures at the centimeter and smaller scale, which may strongly influence multiphase fluid flow and transport properties of preferential flow paths and interaction with the matrix of the surrounding host rock. Pre- and post-UNE rock samples were carefully chosen to enable comparison of fractures as a function of lithologic and petrophysical properties, as well as distance to the past UNEs. This report serves as documentation for the data, including an introduction with the research motivation, a methods and materials section, descriptions of the XRCT datasets without post-processing, and recommendations for 3D quantification via image analysis and digital rock physics.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2026

Bioreactor Optimization through Multi-Phase Flow Models (CRADA Final Report)

Chemical manufacturing uses 29% of energy in the United States and produces 925 million metric tons of CO2 annually. Biomanufacturing offers the potential to leverage America’s rich agricultural resources to produce critical chemicals such as lubricants, pharmaceutical precursors, and components of energetic materials that today are sourced extensively from overseas. The bioreactors used in biomanufacturing applications, such as one developed by Capra Biosciences, involve multiphase flow of biofilm-coated solid support particles that are continuously circulated in a fluidized state within the reactor along with a constant supply of oxygen via an aeration mechanism. In this project, Capra Biosciences and LBNL developed a multiscale modeling framework to simulate the multiphase flows of solid particles in a liquid-gas bubble mixture that occurs in the bioreactor using the current MFIX-Exa software, an opensource multiphase flow solver developed and maintained at LBNL and NETL. By leveraging HPC capabilities, this high-fidelity multiscale model was used to inform design decisions for bioreactor architecture to make them operationally efficient.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

NASA NTRS1994

Towards a Modern Theory of Multiphase Filtration Flow

An alternative theoretical model of joint filtration flow of immiscible incompressible fluids is presented. The model takes into account relaxation processes due to the interchange of the fluids between pores of difference sizes which is driven by capillary forces. The fluids occupy connected regions in a four-dimensional space formed by three coordinates and the pore length scale. When the fluid exchange between pores of given sizes is effected by way of successive flow through pores of all the intermediate sizes, the pressure within each region is governed by a hyperbolic equation, the role of time being played by the pore linear scale. Pressure jumps across hypersurfaces separating the regions equal corresponding values of the capillary pressure. A supplementary condition at any such hypersurface requires the speed of its displacement in the four-dimensional space to coincide with the normal velocity components of both the adjoining fluids. As a result, a principally new statement of multiphase filtration flow problems is gained with allowance for capillary relaxation in the porous space.

Buyevich, Yu A.↗

DOE OSTI2025

Openpronghorn

OpenPronghorn is a simulation tool specifically tailored for modeling thermal-hydraulic phenomena in advanced nuclear reactors. It is built on the Multiphysics Object-Oriented Simulation Environment (MOOSE), an open-source platform that facilitates the development of high-performance scientific computing applications. OpenPronghorn solves the Navier-Stokes equations, which describe the conservation of mass, momentum, and energy in fluid flows, using the finite volume numerical method. The code supports a wide range of fluid flow conditions that are applicable to nuclear reactors, including incompressible and weakly compressible flows, as well as single-phase and multiphase flows. It is capable of modeling diverse flow regimes, including laminar and turbulent flows, using various turbulence models such as the standard k-epsilon models, the v2f model, and the mixing length model. For multiphase flows, OpenPronghorn employs a mixture a Eulerian modeling approach with mixture, drift-flux, and full Eulerian models, and includes open-sourced interfacial transfer correlations for drag, exchange, and heat transfer coming from the scientific literature. OpenPronghorn's modular design allows it to handle multiscale simulations, ranging from detailed Reynolds-Averaged Navier Stokes (RANS) simulations to coarse-mesh and lumped parameter models. This flexibility enables users to perform high-fidelity simulations of specific reactor components as well as system-level analyses of entire reactor circuits. The code can be coupled with other MOOSE-based tools using the MultiApp system, allowing for the transfer of coupling quantities such as mass flow rates, heat fluxes, and boundary conditions between different simulation scales. One of the main features of OpenPronghorn is the it includes built-in validation cases from the open-source scientific literature and supports the implementation of user-defined models and correlations through MOOSE's FunctorMaterial system. OpenPronghorn is designed to be computationally efficient, leveraging the SIMPLE projection method for large-scale problems, and can be run on high-performance computing systems to handle the extensive computational demands of detailed reactor simulations. Overall, OpenPronghorn is a versatile and robust tool that provides critical insights into the thermal-hydraulic behavior of advanced nuclear reactors, supporting the design, safety, and optimization of next-generation nuclear energy systems.

Retamales, Mauricio Eduardo Tano [Idaho National L↗

DOE OSTI2020

Theoretical Review of the MFIX Fluid and Two-Fluid Models

MFIX (Multiphase Flow with Interphase eXchanges) is a general purpose code that can be used for describing the hydrodynamics, chemical reactions, and heat transfer of dense or dilute multiphase fluid flows. MFIX calculations give detailed information on pressure, temperature, composition, and velocity distributions in the defined system. This report provides an overview of MFIX’s expressions for single phase flow and continuous dispersed multiphase flow (i.e., the two-fluid model). In addition to the two fluid model (MFIX-TFM), MFIX contains a discrete element model (MFIX-DEM) and a multi-phase particle in cell model (MFIX-PIC) that are not reviewed within this document.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Pore-Scale Dynamics of Liquid CO2–Water Displacement in 2D Axisymmetric Porous Micromodels Under Strong Drainage and Weak Imbibition Conditions: High-Speed μPIV Measurements

Resolving pore-scale transient flow dynamics is crucial to understanding the physics underlying multiphase flow in porous media and informing large-scale predictive models. Surface properties of the porous matrix play an important role in controlling such physics, yet interfacial mechanisms remain poorly understood, in part due to a lack of direct observations. This study reports on an experimental investigation of the pore-scale flow dynamics of liquid CO 2 and water in two-dimensional (2D) circular porous micromodels with different surface characteristics employing high-speed microscopic particle image velocimetry (μPIV). The design of the micromodel minimized side boundary effects due to the limited size of the domain. The high-speed μPIV technique resolved the spatial and temporal dynamics of multiphase flow of CO 2 and water under reservoir-relevant conditions, for both drainage and imbibition scenarios. When CO 2 displaced water in a hydrophilic micromodel (i.e., drainage), unstable capillary fingering occurred and the pore flow was dominated by successive pore-scale burst events (i.e., Haines jumps). When the same experiment was repeated in a nearly neutral wetting micromodel (i.e., weak imbibition), flow instability and fluctuations were virtually eliminated, leading to a more compact displacement pattern. Energy balance analysis indicates that the conversion efficiency between surface energy and external work is less than 30%, and that kinetic energy is a disproportionately smaller contributor to the energy budget. This is true even during a Haines jump event, which induces velocities typically two orders of magnitude higher than the bulk velocity. These novel measurements further enabled direct observations of the meniscus displacement, revealing a significant alteration of the pore filling mechanisms during drainage and imbibition. While the former typically featured burst events, which often occur only at one of the several throats connecting a pore, the latter is typically dominated by a cooperative filling mechanism involving simultaneous invasion of a pore from multiple throats. This cooperative filling mechanism leads to merging of two interfaces and releases surface energy, causing instantaneous high-speed events that are similar, yet fundamentally different from, burst events. Finally, pore-scale velocity fields were statistically analyzed to provide a quantitative measure of the role of capillary effects in these pore flows.

Li, Yaofa↗

DOE OSTI2025

Derivation of A Representative Elementary Volume (REV) for Upscaled Two-Phase Flow in Porous Media

Relative permeability plays an important role in the upscaling of multiphase flow in porous media from the pore scale to the Darcy scale. The entire concept of relative permeability is contingent on the existence of a representative elementary volume (REV). As we move to smaller samples to measure relative permeability, such as with digital core analysis, the concept of a classical REV has become increasingly unlikely when using the conventional approach to defining a representative volume. The “‘conventional”’ understanding of an REV is that a large enough volume must be considered such that spatial variability averages out. In digital rock methods, such as pore-scale simulations based on micro-computed tomography (CT) images, the domain size is typically 2 to 4 mm. This is approximately the length scale of a single-phase flow REV using the classic REV approach. However, the single-phase perspective does not consider the complex dynamics and fluctuations often observed in multiphase flow systems, even at centimeter-scale experiments and/or simulations. A fundamental question is, therefore, whether the domain size commonly used in digital rock simulations can provide a consistent energy budget such that the concept of relative permeability exists. Based on first principles, relative permeability accounts for the rate of energy dissipated in a stationary process. If the dynamics are fluctuating, the energy dissipated can vary but will average out over a long enough timescale. The key to determining the validity of the relative permeability is the timescale of the measurement, not the spatial scale. The conventional REV theory assumes that spatial, temporal, and ensemble averages are equivalent in an ergodic system, but it does not provide a way to test this assumption. We provide a formal way to identify the timescale where the relative permeability accurately captures energy dissipation as a way to validate relative permeability measurements and quantitatively assess their accuracy. This result will be tested for a practical SCAL test, determining how long a flow experiment needs to be run to accurately characterize the rate of energy dissipation by the flow. The outcome will be a best practice guide for the determination of relative permeability from core-scale experiments and/or digital core simulations that ensure the energy budget is fully accounted for in the relative permeability coefficient.

Mcclure, James [Virginia Tech, Blacksburg]↗

DOE OSTI2019

Device-scale computational fluid dynamics modeling of carbon dioxide absorption using encapsulated sorbents

Micro-encapsulated carbon dioxide sorbent (MECS) is considered to be a promising material for carbon capture system because of high capture rate, low fabrication cost, and efficient energy consumption. To accelerate the development of MECS technology for industrial deployment, device-scale computational fluid dynamics (CFD) simulations are performed to study hydrodynamics and CO2 absorption behavior in a conceptual fluidized bed reactor. The two-fluid model solver, built in the Multiphase Flow with Interphase eXchanges (MFIX), is adopted to solve the multiphase flow hydrodynamics by representing both fluid and solids as continuous phases. Filtered models are implemented to capture the sub-grid effects that normally cannot be directly considered because MECS particles are too small to be explicitly resolved at such a large scale. Using established CFD tools, this study aims to characterize MECS behavior and predict its carbon capture performance in a conceptual device-scale absorber. The MECS particle size and gas flow rate have significant impact on CO2 capture efficiency. The CO2 capture efficiency decreases with increasing gas flow rate. Smaller particle size lead to better gas-solid homogeneity, as a results CO2 absorption efficiency increases.

Wang, Chao (ORCID:0000000279406614)↗

DOE OSTI2017

A Mathematical Model for the Multiphase Transport and Reaction Kinetics in a Ladle with Bottom Powder Injection

A computation fluid dynamics-population balance model-simultaneous reaction model (CFD-PBM-SRM) coupled model has been proposed to study the multiphase flow behavior and refining reaction kinetics in a ladle with bottom powder injection, and some new and important phenomena and mechanisms are presented. For the multiphase flow behavior, the effects of bubbly plume flow, powder particle motion, particle-particle collision and growth, particle-bubble collision and adhesion, and powder particle removal into top slag are considered. For the reaction kinetics, the mechanisms of multicomponent simultaneous reactions, including Al, S, Si, Mn, Fe, and O, at the multi-interface, including top slag-liquid steel interface, air-liquid steel interface, powder droplet-liquid steel interface, and bubble-liquid steel interface, are presented, and the effect of sulfur solubility in the powder droplet on the desulfurization is also taken into account. Model validation is carried out using hot tests in a 2-t induction furnace with bottom powder injection. The result shows that the powder particles gradually disperse in the entire furnace; in the vicinity of the bottom slot plugs, the desulfurization product CaS is liquid phase, while in the upper region of the furnace, the desulfurization product CaS is solid phase. The predicted sulfur contents by the present model agree well with the measured data in the 2-t furnace with bottom powder injection.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Systems and methods for convex relaxations and linear approximations for optimal power flow in multiphase radial networks

Centralized node controllers in accordance with embodiments of the invention enable linear approximation of optimal power flow. One embodiment includes a centralized node controller including: a network interface, a processor, and a memory containing: a centralized power control application a network topology, where the network is multiphase unbalanced and comprises a plurality of connected nodes; wherein the processor is configured by the centralized controller application to: request node operating parameters from the plurality of connected nodes; calculate network operating parameters using a linear approximation of optimal power flow and the node operating parameters from the plurality of connected nodes; send network operating parameters to the plurality of connected nodes.

97 MATHEMATICS AND COMPUTING↗