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At least 343 records · Page 19
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Report on Year-4 of Water NSTF Matrix Testing: Facility Maintenance and Accident Testing

Under support from the Department of Energy (DOE) and the Office of Advanced Reactor Technologies (ART), a large-scale test facility has been constructed at Argonne National Laboratory to generate NQA-1 qualified validation data for passive decay heat removal systems in advanced reactors. The Natural convection Shutdown heat removal Test Facility (NSTF) reflects key features of a ½ scale, water-based, Reactor Cavity Cooling System (RCCS) and is intended to study the behavior, bound performance, and ultimately guide design decisions for passive decay heat removal systems for advanced reactors. In addition to the experimental activities detailed in this report, a supportive computational modeling effort is on-going which has been demonstrated to significantly strengthen the experimental program while also improving accuracy of the computer models. Together these create a mutually beneficial relationship integral to meeting the overall program objective of examining the heat removal performance of the RCCS concept. This report serves as a summary of maintenance and experimental activities during the program’s fourth year of water-based operation. A planned six-month maintenance period began in August 2021, during which major inspections, repairs, cleaning, and installation of new instrumentation and data acquisition hardware were conducted. Most significantly, two heaters that faulted during Year-3 were repaired, allowing the facility to resume use of the full heated section area and full range of available electric power. The remainder of the year consisted of eight months of test operations, during which the facility logged 211 hours of active heating across one bake-out (following the maintenance period) and seven matrix tests; five classifieds as Accepted per NQA-1, one as Trending, and one as Failed. Testing began by performing two repeat cases to confirm expected facility response and behavior during both single- and two-phase flow conditions, ensuring no changes were introduced during the maintenance period that might have altered the thermal-hydraulic characteristics of the facility. In continuation of the power parametric series initiated in previous years, a high-power test case was then performed examining heat removal performance at a decay heat load equivalent to 2.4 MWt, full-scale, a level exceeding maximum design targets. Additional testing then introduced various blockage scenarios along the network piping, examining the effects of partial and complete blockages of the flow paths on the system behavior and heat removal performance. A study of static boiling tests directed at understanding the geysering two-phase instability was also conducted. The loop was filled only to the bottom of the tank outlet, creating an open loop configuration that prevents any natural circulation flow from occurring, and the heaters were powered on until the facility reached saturation conditions. Following, a series of quasi-steady-state conditions were introduced by adjusting the inventory level in the adiabatic chimney piping at decreasingly lower elevations above the heated region. A strong correlation of geysering characteristics and loop level was observed, with flow and temperature excursions decreasing in intensity, but increasing in frequency, as the fill were reduced to lower elevations along the chimney piping. Once the level fell very low in the chimney, at points near the top of the heated section, the system reached a stable state of continuous boiling without any occurrence of geysering eruptions. A final significant testing accomplishment this year was successful completion of an “accident scenario” test, whose operating conditions were based on a prototypic decay heat curve provided by Framatome and scaled for the NSTF. This test began by establishing steady-state, single-phase “normal operation” conditions, before simulating an accident trip where the availability of active cooling systems was lost. Loop temperatures gradually increased until reaching saturation and subsequent two-phase boiling flow. Over the course of an extended operational period along the defined decay heat curve, steam boil-off caused gradual but continued depletion of liquid inventory until reaching a critically low level causing flow stagnation and cessation of natural circulation heat removal. At this point, after nearly 72 hours of continuous operation, a cold refill was performed to replenish the system inventory and allow the facility to re-establish closed loop natural circulation flow and return to a safe operational state.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

High-temperature corrosion of a nickel-based alloy in a molten chloride environment – The effect of thermal and chemical purifications

There is currently an ever-increasing demand for higher process efficiencies in next generation (Gen3) concentrating solar power (CSP). Higher process efficiencies may be procured by increasing the operating temperature, and simultaneously, minimizing the degradation of materials used for construction of CSP plants (e.g., piping, thermal storage tanks, solar receivers and heat exchangers). Thus, understanding materials corrosion in the presence of molten salt mixtures used as thermal energy storage media and heat transfer fluids is indispensable for CSP development. The present paper provides insights into the effects of salt purification on the corrosion of a nickel-based alloy (Haynes 230) isothermally exposed to a stagnant chloride-based salt mixture at 800 °C. The MgCl 2 -based salt mixture was thermally dehydrated and chemically treated with (0.1 and 0.5 wt %) elemental magnesium. Results reveal the electrochemical nature of the corrosion process, and the formation of corrosion products such as oxides (MgO, MgCr 2 O 4 , and MgAl 2 O 4 ) and nitrides (CrN) on the alloy surface and in sub-surface regions. Magnesium additions enhanced the ability to resist corrosion by reducing the concentration of impurities (H 2 O, MgOH + , OH - species) and polarizing the alloy surface. The formation of nitrides in all cases studied indicates the impact of using nitrogen as a protective gas in the system. Results also reveal that a single step treatment of the salt using metallic Mg could be considered as a measure to control the salt's impurity level, e.g., if required for system control.

14 SOLAR ENERGY↗
DOE OSTI2021

Fluid dynamic simulation and analysis of water-cooling systems for the Electron-Ion Collider

The Electron-Ion Collider is the newest large-scale project at Brookhaven National Laboratory. The collider’s purpose is to provide further advancements in the knowledge of the universe’s origin by accelerating particles near the speed of light. Our project for this 3.8 km ring was to create a thermal hydraulic steady-state simulation design of the water-cooling system to be cost-effective and energy efficient, as envisioned by Charlie Foltz, the EIC Infrastructure Division Director. The system would include a supply and return header, which cools several thousand components of the ring. The water would then be returned and cooled down using a system of cooling towers and plate and frame heat exchangers. Due to the size of the system and the complexity of the network analysis, a fluid dynamic simulation software, AFT Fathom, was used. Since previous methods of maintaining systems relied on building upon smaller real-life models and implementing empirical data, this flow model was unique and first of a kind in the domain of accelerator design, construction and operation. Therefore, our hydraulic team piloted a new method to perform network analysis on a large scale cooling system. We successfully created several test scenarios for system behavior in a shorter time compared to the method of performing hand calculations. Cooling specifications for heat rejection, pressure drop, flow rate, and pipe sizing were changed based on the individual systems of the vacuum, radio frequency (RF), magnet and power supply, and cryogenics sections. Finally, we used DOE guidelines to perform life-cycle cost analysis with net present value and carbon saving analysis on the systems where pipe size could be optimized.

43 PARTICLE ACCELERATORS↗
DOE OSTI2026

Predicting roughness effects in additively manufactured coolant channels with helical enhancements

Additive manufacturing (AM) is a promising technique for fabrication of complex geometries such as those expected to be utilized in the blanket, first wall, and divertor. In the case of cooling, metallic AM may be exploited to embed geometric enhancements (ribs, rifling, etc.) to improve cooling performance. However, due to the roughness of these unfinished internal AM surfaces, prediction of thermal hydraulic performance in such channels is difficult. In this work, we consider a methodology for predicting pressure drop and heat transfer in AM channels containing helical enhancements (e.g. helical ribs, twisted tapes) that allows the incorporation of roughness data through conventional pipe flow correlations. This methodology is tested using experimental friction factor and heat transfer coefficient data from high-pressure helium coolant flow measurements in AM stainless steel tubes fabricated by laser powder bed fusion. Both a featureless AM tube and one containing helical ribs were considered alongside a conventionally manufactured smooth tube. The AM surface roughness is obtained by profilometry and used to predict an equivalent sand-grain roughness, with this equivalent roughness confirmed through AM featureless tube measurements. Under the proposed methodology, this roughness information is incorporated into predictions of friction factor and Nusselt number for the rifled tube. Furthermore, these predictions agree well with experimental data across a large range of Reynolds numbers, encouraging the use of this methodology for thermal hydraulic analysis of similar systems and design of future coolant channel geometries.

Additive manufacturing↗
DOE OSTI2022

Impact of Fuel Properties on the Combustion of Late Post Injections used for Aftertreatment Thermal Management

Typical calibration for catalyst thermal management for compression-ignition engines involves delaying the post-injection into the expansion stroke. Reduced work extraction due to the late heat release event is used to increase the exhaust gas temperature to shorten the time associated with reaching optimal temperatures for aftertreatment systems. Shorter catalyst heat-up time can simultaneously reduce tail-pipe emissions and the typical fuel penalties associated with this mode of operation. In this study, the effects of volatility, reactivity, and oxygen content of the fuel on combustion stability and emissions were studied in a light-duty single-cylinder research engine. Blends of iso-octane/ n-heptane and farnesane/ 2,2,4,4,6,8,8-heptamethylnonane were used to study the impacts of volatility and reactivity. At constant reactivity, little to no variation in combustion performance was observed due to differences in volatility. On the other hand, increased reactivity improved combustion stability and efficiency at late injection timings (+24 CAD). The combined effect of increase in chemical reactivity and oxygen content was analysed by comparing the baseline #2 diesel operation with two blends of mono-ethers and #2 diesel to achieve cetane numbers (CNs) of 45 and 55, and a pure blend of mono-ether components with CN > 100. Fuels with higher reactivity and oxygen content were found to reduce engine-out hydrocarbon and carbon mono-oxide emissions while also achieving stable combustion at post-injection timings later than those achievable with diesel fuel. The pure ether-blend had the latest achievable post-injection timing (≥+26 CAD) while still maintaining stable combustion. At similar combustion stability, the pure ether blend was found to have 2.8% higher combustion efficiency and 4.3% higher thermal efficiency than the baseline diesel. The ether-diesel blends at CN45 and CN55 were found to have 1.8% higher combustion efficiency than baseline diesel. The results demonstrate that fuels with increased reactivity can increase combustion efficiency, reducing carbon monoxide and hydrocarbon emissions, while maintaining similar exhaust temperature and combustion stability compared to baseline diesel. Further greenhouse gas benefits can also be realized as the mono-ether bioblendstocks show potential for >50% reduction in greenhouse gas emissions relative to diesel fuel based on their production method.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2024

FY24 Report on Water NSTF Testing: Lower Tank Inlet Piping Configuration

The following report serves as a summary of the accomplishments and testing results by the Natural convection Shutdown heat removal Test Facility (NSTF) experimental program over the past 12-month period. A major activity included reconfiguration of the chimney piping geometry which altered the discharge position into the tank from the original 50% tank height to a new lower position at a 10.9% tank height. This modification increases the volume of available coolant thus extending long-term operating capacity, however also results in a decreased liquid driving head which has the potential to reduce the natural circulation efficiency and decrease overall performance. Examination of the tradeoffs for these two configurations is an area of interest for RCCS designers and drove planned test activities this year. Ten matrix tests were performed in FY24, totaling 195 hours of heated operations and 12.9 MWh of electrical heating throughout the year, with eight classified as Accepted per NQA-1 and two classified as Trending. Testing prior to the facility reconfiguration examined the facility response to throttling at the tank inlet, demonstrating increased sensitivity of flow instabilities to throttling within the two-phase region when compared to throttling at the lower sensitivity single-phase inlet region. Testing after the chimney reconfiguration began with a baseline test at conditions of 80% inventory fill and prototypic thermal power input of 2.1 MW t . In addition to establishing a reference for nominal system behavior and performance, repeat testing with multiple subsequent runs demonstrated strong repeatability between tests performed at the same conditions in this new configuration. These tests also examined if influences would occur to system behavior with installation of new higher-resolution instrumentation within the upper chimney. In this critical region where boiling and flashing phenomena dominate, the test results provided confidence that the new instrumentation does not uncharacteristically influence the observed behaviors. An inventory parametric series was then initiated to examine system behavior with the new chimney configuration at six varying initial inventory levels, ranging from high 80% to low 20% fill. Two-phase oscillations with similar peak and mean flow rates were observed when comparing to the previous mid tank configuration. Generally, similar system response trends with inventory were also observed, such as two phase oscillations suppressing as inventories were lowered. However, in one absolute inventory comparison at the highest fill of 80%, flow oscillations saw a gradual growth over the 4 hours of two-phase operation in the new lower tank inlet configuration, opposite of the gradual dampening observed in the mid tank inlet configuration. This can be attributed to, in part, a greater hydrostatic head pressure above the two-phase discharge region where the boiling front is developed. Furthermore, the change resulted in greater sensitivity to liquid degassing phenomena during single-phase heating, causing loop instabilities to form which trigged moderate flow degradation during the period approaching saturation and boiling conditions. This behavior had been observed previously under some conditions but was a common occurrence in recent testing with the newer lower tank inlet configuration. Initial observations from these first data sets suggest an overall larger window of stability for the mid tank inlet configuration compared to the lower tank inlet. Lastly, the lowest inventory fill test was repeated over an extended testing window to examine depletion behavior. Natural circulation flow and effective heat removal performance were observed during most of the testing period; only after the tank became fully drained (0% fill) did flow stagnate and violent geysering events occur. This early observation confirms one relative advantage over the mid tank inlet configuration, which stagnated under comparable conditions at ~20% inventory remaining in the tank.

42 ENGINEERING↗
DOE OSTI2026

Technical Justifications for Outdoor Bulk Gaseous Hydrogen Storage Setback Distances

Setback distances define a prescribed distance between a potentially hazardous system and different types of other systems, people, buildings, or materials that may be exposed to that hazard. Riskinformed separation distances are not meant to completely eliminate risk, but rather to limit the risk to an acceptable level. A sensitivity study of risk suggested that a leak size of 3% of the pipe cross-sectional area would be a conservative but reasonable basis. Calculation of the setback distances for gaseous hydrogen was done in a deterministic manner, using a selected leak size and harm criteria for each group of exposures. Harm criteria have been updated to better reflect the exposure types under consideration, and to be consistent with setback distances for liquid hydrogen. The resulting setback distance values are primarily driven by radiative heat flux values for all exposure groups. For the typical pipe sizes, the setback distances slightly increase compared to the previous version of NFPA 2.

08 HYDROGEN↗
DOE OSTI2021

Review and Analysis of Heat Transfer Correlations For Horizontal Pseudocritical CO 2 Heat Exchanger Applications

There is significant interest in the development of supercritical carbon dioxide (sCO 2 ) power cycles because of the potential for smaller and more energy efficient systems than a steam Rankine cycle. Heat exchanger designs typically use empirical correlations, but the applicability of these correlations near the CO 2 critical point is a potential issue. Though numerous correlations have been proposed in the literature, there are some disagreements when it comes to the accuracy. The current work recognizes the role of thermophysical properties, and its impacts on the heat transfer correlations and cycle efficiency. Heat transfer correlations proposed for horizontal flow inside circular pipes were analyzed with the help of numerical simulations. Steady state RANS simulations were performed using SST k-w turbulence model to evaluate the Nusselt number empirical correlations. It was found that the most of correlations (except Yoon) produced a Nusselt number that differed significantly with the one predicted numerically. Some of the correlations were developed for pure forced convection regime and as mentioned in Lin et al. do not account for mixed convection or free convection effects. Based on the limited observation, it appears that Yoon et al. predictions match well with the numerically predicted Nusselt Numbers. However, further analysis is required understand the applicability of various correlations and is contingent on accurate measurements or predictions of wall temperature profiles in the axial and the circumferential directions.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

Thermoelectric coatings for waste heat recovery and photo-thermal power

An energy harvesting system for collecting energy from sources of thermal energy that exist in the environment and convert the energy to electricity. The system has N-P junctions mounted on the outer surface of a conduit, pipe or flue. A hot medium flows through the conduit, pipe or flue. The p-n junctions operate as thermoelectric power generators. Heat absorbed at the p-n junctions increases the kinetic energy of charge carriers causing migration of the charge carriers. This thermally-driven migration of charge carriers is used to drive an electrical current in an external circuit.

Farmer, Joseph C.↗
DOE OSTI2022

Electron Cloud Simulations for the Electron-Ion Collider in Brookhaven National Laboratory

For high-intensity circular accelerators and storage rings, if the secondary electron emission yield (SEY) of the vacuum chamber surfaces is high, an EC (Electron Cloud) could build up with the passage of the circulating beam. The presence of EC can strongly affect the beam quality, such as transverse instabilities, transverse emittance growth, and beam loss. Furthermore, the heat load from EC can exceed the available cryogenic capability. For the RHIC superconducting (SC) arc magnets, to be used for the hadron storage ring of the Electron-Ion Collider (EIC), the dynamic heat load budget is 0.5 W/m to the 4.5 K stainless steel beam pipe. This can limit the maximum beam bunches or intensity of the EIC, hence diminishing the luminosity provided by the EIC. The EC has affected the beam instability and significantly contributed to cryogenic heat load in the Large Hadron Collider (LHC). Positron storage rings for which ECs have been a critical factor in the design and performance include KEKB in Japan and EC buildup remains one of the concerns for future high-intensity accelerators design. EC considerations have driven the SuperKEKB collider design and the positron damping ring for the proposed International Linear Collider (ILC). The LHC luminosity upgrade is contingent on reducing the bunch spacing to 25 ns; at this bunch spacing, severe EC buildup has been observed. The success of the upgrade is likely contingent on limiting EC buildup. To study the EC heat load, we did some EC simulations with PyECLOUD code for the dipole, quadrupole, sextupole magnets, and the warm (drift) section of the EIC hadron storage ring. PyECLOUD is an EC simulation code developed by CERN. The code has been validated and used to study EC in the LHC, SPS, and PS. To eliminate EC buildup, the sources of electrons must be minimized. First, we will reduce the production of electrons due to residual gas ionization by specifying the maximum gas density, which requires a vacuum chamber with low electron-stimulated desorption (ESD) yields and a sufficient (preferably distributed) pumping speed. Second, we should reduce the secondary electrons with a lower secondary electron yield (SEY) material.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

Experimental demonstration of >20 kJ laser energy coupling in 1-cm hydrocarbon-filled gas pipe targets via inverse Bremsstrahlung absorption with applications to MagLIF

Laser propagation experiments using four beams of the National Ignition Facility to deliver up to 35 kJ of laser energy at 351 nm laser wavelength to heat magnetized liner inertial fusion-scale (1 cm-long), hydrocarbon-filled gas pipe targets to ~keV electron temperatures have demonstrated energy coupling >20 kJ with essentially no backscatter in 15% critical electron density gas fills with 0–19 T applied axial magnetic fields. The energy coupling is also investigated for an electron density of 11.5% critical and for applied field strengths up to 24 T at both densities. This spans a range of Hall parameters 0 < ω ce τ ei ≲ 2, where a Hall parameter of 0.5 is expected to reduce electron thermal conduction across the field lines by a factor of 4–5 for the conditions of these experiments. At sufficiently high applied field strength (and therefore Hall parameter), the measured laser propagation speed through the targets increases in the measurements, consistent with reduced perpendicular electron thermal transport; this reduces the coupled energy to the target once the laser burns through the gas pipe. In conclusion, the results compare well with a 1D analytic propagation model for inverse Bremsstrahlung absorption.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2024

Assessment of a Grade 91 Steel Forging and Seamless Pipe Section After 141,000-Hours of Operation in a Superheat Outlet Header

In this work, two unique heats of 9Cr creep strength enhanced ferritic (CSEF) steels extracted from a retired superheat outlet header after 141,000 hours of service were evaluated. These two CSEF steels were a forging manufactured to SA-182 F91 (F91) reducer and a seamless pipe produced to SA-335 P91 (P91) pipe. Their creep deformation and fracture behavior were assessed using a lever arm creep frame integrated with in-situ high-temperature digital image correlation (DIC) system. Critical metallurgical and microstructure factors, including composition, service damage, grain matrix degradation, precipitates, and inclusions were quantitatively characterized to link the performance of the two service aged F91 and P91 CSEF steels. The creep test results show the F91 and P91 steels exhibit a large variation in creep strength and creep ductility. The F91 steel fractured at 572 hours while P91 steel fractured at 1,901 hours when subjected to a test condition of 650 °C and 100 MPa. The nominal creep strains at fracture were 12.5% (F91) and 14.5% (P91), respectively. The high-resolution DIC strain measurements reveal the local creep strain in F91 was about 50% while the local creep strain in P91 was >80%. The characterization results show that the F91 steel possessed pre-existing creep damage from its time in service, a higher fraction of inclusions, and a faster matrix grain coarsening rate. These features contribute to the observed reduction in performance for the F91 steel. The context for these findings, and the importance of metallurgical risk in an integrated life management approach will be emphasized.

Wang, Yiyu↗
DOE OSTI2024

Preliminary Design of Nuclear Reactor Heat Delivery Systems: Integration with Reference Oil Refinery, Methanol Synthesis, and Hydrogen Production

The Department of Energy’s (DOE) Integrated Energy Systems (IES) program is generating comprehensive analyses validating the opportunity for using nuclear energy in a variety of applications including future clean grids, providing heat for direct use, and providing heat to help reduce emissions in chemical commodities. This work focuses on the preliminary designs of thermal delivery systems that can integrate heat produced from a nuclear core to industrial processes. The key research question that needs to be answered is: what is the prospective method for integrating nuclear generated heat energy into non-electric applications that can facilitate combined heat and power operations by advanced nuclear reactor systems? This research is a composition of case studies showing preliminary conceptual designs for thermal delivery systems integrating advanced nuclear systems with a few industrial systems including high temperature steam electrolysis, a reference oil refinery, and potential future methanol systems that supplant some natural gas use with nuclear energy. Piping and instrumentation diagrams have been developed to show the conceptual integration of nuclear systems with representative industrial systems. Different features of the configurations are dependent on the specific integration requirements including energy source conditions, demand quantity, and require energy application conditions. Design concepts are validated using thermodynamic balance calculations to verify system performance including calculating system losses during transport. Key components: pumps and compressors, heat exchangers, and network piping are reported with key design information and sizing.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Effect of self-generated magnetic fields on x-ray emission in Kr-filled targets at the National Ignition Facility

We examine the effects of self-generated magnetic fields in a Kr gas pipe x-ray source platform. X-ray emission from Kr plasma is dependent on the plasma conditions, as the ionization state is largely a function of temperature. Magnetic fields are known to limit heat conduction, which increases temperature. We show that the emission in simulations of the gas pipe x-ray source is dependent on how self-generated magnetic fields are modeled. The inclusion of self-generated magnetic fields in simulations more accurately captures the emission of lower energy x-ray emission (L-shell), bringing results closer to experiments. The modeled x-ray emission and self-generated magnetic fields are shown to be particularly sensitive to the inclusion of the Nernst effect in simulations. Severely limiting the Nernst effect leads to a hotter Kr plasma, which can account for the discrepancy seen in earlier studies. By modifying the Nernst effect multiplier, we can achieve better experimental agreement in x-ray emission from gas pipes; the value of the multiplier that leads to the best agreement is dependent on the laser power of the drive. Currently, the suppression factor of the Nernst effect needed for high power drives (PL>200 TW) is more restrictive than what is currently put forward by non-local models.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Enhancement of operational Flexibility of Power Plants Using IN740

Headers are crucial components within diverse industries, especially in the energy sector, as they enable the efficient transfer of fluids. The selection of materials for headers is determined by their specific applications; for example, Grade 91 and Grade 92 steels are commonly utilized. In our research, we recommend the adoption of INCONEL alloy 740 due to its exceptional robustness and heat-resistant characteristics. One critical parameter in header systems is the heat transfer coefficient, which directly influences the efficiency of heat exchange processes and can thereby impact the structural integrity of the headers. This coefficient is closely linked with factors such as the Nusselt number, which is influenced by fluid flow characteristics and thermal properties. The flow direction within headers, whether unidirectional or multidirectional—significantly affects the overall dynamics of heat transfer. This research focuses on exploring the behavior of headers, a specific pipeline system component, using ANSYS simulation software. The study aims to predict heat transfer and mechanical behavior within headers under various conditions through steady-state and transient simulations (parts 1 and 2 of the report). Key parameters such as heat transfer coefficient, velocity, and temperature are examined with the goal of optimizing header design. Part 3 of the report addresses the critical yet underexplored relationship between pressure drop and heat transfer coefficients in the transient flow regime within headers, specifically focusing on smooth horizontal circular tubes. Limited experimental work has been conducted in this area, prompting the need for comprehensive analysis. By leveraging machine learning techniques, this research aims to establish a correlation between pressure drop and heat transfer across various flow conditions, including laminar, transient, quasi-turbulent, and turbulent regimes. The data utilized for this analysis were meticulously gathered from existing literature, capturing simultaneous measurements of pressure drops and heat transfer. Part 4: In the context of power plants, header pipes are essential components that significantly influence system performance by facilitating the collection and distribution of steam. This report highlights the critical role of header pipes in enhancing reliability, efficiency, and overall power plant performance. A key aspect of this investigation is shape optimization, which aims to maximize performance while minimizing material usage. By focusing on shape optimization, this research contributes to improved efficiency and a reduced environmental footprint for power plant installations. The methodology developed in this study emphasizes optimizing header shapes to decrease reliance on expensive alloy materials and lower maintenance costs. Furthermore, a case study was conducted using a header from an operational power plant to validate the proposed optimization techniques. Finally, part 5 addresses the challenges associated with flexible operations in boiler systems, the study outlines several strategies for enhancing the durability and reliability of steam headers. Key approaches include material selection, which involves utilizing advanced materials with superior high-temperature properties and enhanced fatigue resistance to extend the lifespan of steam headers. Design modifications are also recommended, focusing on implementing changes that mitigate thermal stress and cyclic loading to reduce the likelihood of failures under varying operating conditions. Additionally, the study emphasizes the importance of regular inspection and monitoring by establishing rigorous protocols to detect early signs of damage, allowing for timely maintenance and minimizing the risks of catastrophic failures. Furthermore, operational guidelines are developed to minimize the frequency and severity of thermal transients, ensuring stable and efficient operations. Collectively, these strategies provide a robust framework for overcoming the unique challenges posed by flexible operation in boiler systems, ultimately contributing to improved reliability and performance in power plant operations. Through this comprehensive approach, the study not only enhances the understanding of pressure drop and heat transfer relationships but also promotes advancements in design and operation that will benefit the entire power generation industry.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2023

Control development and sizing analysis for a 5th generation district heating and cooling network using Modelica

5th generation district heating and cooling system (5GDHC) are a relatively new concept. They use a single district loop near ambient temperature to provide heating and cooling. This paper improves on the modelling and control of a 5GDHC system called the reservoir network. The study updates the sewage heat exchanger plant model to more realistically represent seasonal changes, uses refined pump models with variable efficiency, introduces a ground coupled district pipe model to consider the inertia of the district network and implements a new control strategy for geothermal storage and sewage heat exchanger. The new approach reduced operating costs, mainly due to pumping cost for storage, sewage heat exchanger plant and distribution pump, while increasing the overall robustness of the approach in different sizing conditions. Thanks to the new controller, the pumping consumption was reduced by 21% with respect to the original baseline. Furthermore, the new control makes the system take better advantage of design changes, when reducing borehole field size and increasing the sewage heat exchanger size, the pumping energy savings become 29% with respect to the original baseline. Lastly, borehole field temperature stability was analyzed through 40 years of simulation.

Zanetti, Ettore↗
DOE OSTI2024

Preliminary Assessment of Additively Manufactured Cooling Channel Performance for Helium-Cooled Blanket Concepts

Sufficient cooling of the blanket first wall remains a critical challenge for the design and deployment of fusion power plants. Helium has been targeted as a potential blanket coolant due to its inertness and low neutron interactivity, among other advantages. However, the low thermal mass of helium creates a need for heat transfer enhancements in coolant channels to provide adequate cooling to the blanket’s first wall. Toward this end, a series of ribbed flow channels of various rib cross sections and configurations has been produced via additive manufacturing (AM) to study the efficacy of AM for first wall heat transfer enhancement and the optimization of heat transfer geometries. Helium cooling performance is studied in AM test articles at 4 MPa operating pressure, Reynolds numbers up to 197 000, and outer surface heat fluxes up to 42 kW/m 2 in the recently commissioned helium flow loop experiment (HFLE). Preliminary results of this study are presented herein. Heat transfer performance of nominally smooth (i.e., featureless) AM channels is quantified via measured Nusselt numbers and friction factors and compared to off-the-shelf smooth pipe experiments. Results are compared to existing correlations and used to discuss the effects of the AM processes on thermal-hydraulic performance. It is seen that the inherent roughness of the AM channels leads to an increase in both heat transfer coefficient and pressure drop when compared to the conventional pipe. In conclusion, recommendations are made for future studies based on these findings and additional considerations for the deployment of AM blanket cooling components.

36 MATERIALS SCIENCE↗
DOE OSTI2020

RELAP-7 Application and Enhancement for FLEX Strategies and ATF Behavior under Extended Loss of AC Power Conditions

This report summarizes the results of a three-year research project sponsored by the U.S. Department of Energy (DOE) Nuclear Energy University Program (NEUP) to enhance and apply the RELAP-7 code by adding and improving several important components (e.g., a mechanistic Reactor Core Isolation Cooling (RCIC) system model) for thermal hydraulic studies of LWRs under ELAP conditions and evaluating the time available for transition to portable FLEX equipment. The project team included University of Massachusetts–Lowell, The Ohio State University, Texas A&M University, Idaho National Laboratory and Oak Ridge National Laboratory. In the Fukushima accident, it was found that the RCIC system played a crucial role in delaying core meltdown by almost three days in Fukushima Daiichi Unit 2, because of self-regulated operation of the steam driven RCIC turbine-pump injection system. Steam flow in the convergent-divergent nozzles of the RCIC Terry turbine is two-phase non-equilibrium transonic flow with homogenous nucleation condensation. To more accurately predict the dynamic process and behavior of the transonic compressible steam flow, a one-dimensional transient two-phase analytical model is presented. A simplified four-fluid model was employed in the present work with the consideration of four separate fluid fields: vapor, liquid film, entrained droplets and condensed droplets. The mass, momentum and energy interactions between the fluids were considered and modeled. An extended seven-equation non-equilibrium critical flow model was developed to obtain the critical pressure and velocities of each phase at the nozzle throat. To predict the wetness in the divergent section, a mechanistic nucleation condensation model was integrated in the nozzle analysis model, considering the generation and consequent growth of droplets. The governing differential equations on a staggered grid were discretized using the second-order Lax-Wendroff scheme with a flux limiter, and the Semi-Implicit Method for Pressure-Linked Equation (SIMPLE) algorithm was employed to solve the discrete linear system. To demonstrate the predictability and reliability of the physical models and the numerical method proposed in the present work, three representative nozzles were modeled and simulated. The results show good agreement with the available experimental data, even for condensation shock. Then, the 1D nozzle model was employed to obtain nozzle flow tables of the Terry turbine nozzle for different working pressures which can cover the operation pressure range of the RCIC system. A mechanistic RCIC turbine-pump system model was developed and implemented in the system code TRACE to simulate dynamic responses of the RCIC system under Beyond Design Basis Accident (BDBA) conditions. The turbine-pump governing equations are based on the control volume approach of the angular momentum balance. The physics based mechanistic RCIC model was developed using the TRACE control system components (i.e., signal variables, control blocks, and tables), and incorporated into a TRACE boiling water reactor (BWR) model. The TRACE model in this report has a detailed nodalization of the reactor pressure vessel (RPV), and all of the major flow paths and system components, including the safety relief valves (SRVs) and the containment suppression pool and drywell. Based on the nozzle flow tables generated from the 1D nozzle model developed, the turbine drive torque can be calculated from table lookup. Since the detailed specifications of the RCIC pump are unavailable, the homologous curves for a Bingham pump were used in the current pump component. A station black-out (SBO) accident test problem was selected to demonstrate the TRACE RCIC model. The short-term SBO simulations were performed for two cladding materials: Zircaloy and FeCrAl, to demonstrate the effect of the accident tolerant fuel cladding on fuel heat-up under BDBA accident conditions. The wetwell plays a vital safety role in SBO and other BWR accident scenarios in that it can reduce containment pressure and supply additional core make-up water. The suppression pool temperature distribution has a very large impact on both RPV and containment pressure. Thus, another novel contribution of the project comes mainly from an improved, systems-level wetwell model which can capture buoyancy-induced thermal stratification effects due to steam injection and condensation. A two-zone stratified wetwell model has been implemented in RELAP-7 and some results from that model are presented. This wetwell model is capable of simulating thermal stratification due to a low steam mass injection rate. With a low mass flow rate, the model assumes that all the steam condenses within the pipe and the resulting plume can be approximated with a purely buoyant, heat-source driven model. The wetwell model developed with these assumptions is adequate to simulate slow transients such as extended SBO transients.

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