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This revised AMO steam tip sheet on upgrading boilers provides how-to advice for improving industrial steam systems using low-cost, proven practices and technologies.
A double-wall-tube is nominated for the steam generator heat transfer tube of future sodium fast reactors (SFRs) in Japan, to decrease the possibility of sodium/water reaction. The double-wall-tube consists of an inner tube and an outer tube, and they are mechanically contacted to keep the heat transfer of the interface between the inner and outer tubes by their residual stress. During long term SG operation, the contact stress at the interface gradually falls down due to stress relaxation. This phenomenon might increase the thermal resistance of the interface and degrade the tube heat transfer performance. The contact stress relaxation can be predicted by numerical analysis, and the analysis requires the data of the initial residual stress distributions in the tubes. However, unclear initial residual stress distributions prevent precious relaxation evaluation. In order to resolve this issue, a neutron diffraction method was employed to reveal the tri-axial (radius, hoop and longitudinal) initial residual stress distributions in the double-wall-tube. Strain gauges also were used to evaluate the contact stress. The measurement results were analyzed using a JAEA's structural computer code to determine the initial residual stress distributions. Based on the stress distributions, the structural computer code has predicted the transition of the relaxation and the decrease of the contact stress. The radial and longitudinal temperature distributions in the tubes were input to the structural analysis model. Since the radial thermal expansion difference between the inner (colder) and outer (hotter) tube reduces the contact stress and the tube inside steam pressure contributes to increasing it, the analytical model also took these effects into consideration. It has been conduced that the inner and outer tubes are contacted with sufficient stresses during the plant life time, and that effective heat transfer degradation dose not occur in the double-wall-tube SG. (authors)
The Westinghouse Small Modular Reactor (SMR) is an 800 MWt (>225 MWe) integral pressurized water reactor (iPWR), in which all of the components typically associated with the nuclear steam supply system (NSSS) of a nuclear power plant are incorporated within a single reactor pressure vessel. This paper is the first in a series of four papers which describe the design and functionality of the Westinghouse SMR. Also described in this series are the key drivers influencing the design of the Westinghouse SMR and the unique passive safety features of the Westinghouse SMR. Several critical motivators contributed to the development and integration of the Westinghouse SMR design. These design driving motivators dictated the final configuration of the Westinghouse SMR to varying degrees, depending on the specific features under consideration. These design drivers include safety, economics, AP1000{sup R} reactor expertise and experience, research and development requirements, functionality of systems and components, size of the systems and vessels, simplicity of design, and licensing requirements. The Westinghouse SMR NSSS consists of an integral reactor vessel within a compact containment vessel. The core is located in the bottom of the reactor vessel and is composed of 89 modified Westinghouse 17x17 Robust Fuel Assemblies (RFA). These modified fuel assemblies have an active core length of only 2.4 m (8 ft) long, and the entirety of the core is encompassed by a radial reflector. The Westinghouse SMR core operates on a 24 month fuel cycle. The reactor vessel is approximately 24.4 m (80 ft) long and 3.7 m (12 ft) in diameter in order to facilitate standard rail shipping to the site. The reactor vessel houses hot and cold leg channels to facilitate coolant flow, control rod drive mechanisms (CRDM), instrumentation and cabling, an intermediate flange to separate flow and instrumentation and facilitate simpler refueling, a pressurizer, a straight tube, recirculating steam generator, and eight reactor coolant pumps (RCP). The containment vessel is 27.1 m (89 ft) long and 9.8 m (32 ft) in diameter, and is designed to withstand pressures up to 1.7 MPa (250 psi). It is completely submerged in a pool of water serving as a heat sink and radiation shield. Housed within the containment are four combined core makeup tanks (CMT)/passive residual heat removal (PRHR) heat exchangers, two in-containment pools (ICP), two ICP tanks and four valves which function as the automatic depressurization system (ADS). The PRHR heat exchangers are thermally connected to two different ultimate heat sink (UHS) tanks which provide transient cooling capabilities. (authors)
The hydrogen uptake during steam oxidation of Zircaloy-4 and E110 was investigated in-situ in the temperature range of 1000 to 1300 deg. C. The procedure to determine hydrogen concentrations from the neutron radiographs measured is explained in detail. Very fast hydrogen absorption (<10 s) was observed directly after start of the steam injection. The maximal hydrogen concentration reached increases with increasing temperature. After this first fast hydrogen uptake a slight release of hydrogen was observed. The hydrogen concentration depends on time with the power of -1/8. An enhanced hydrogen uptake occurs if oxidation switches into the breakaway mode. The hydrogen concentration increases by nearly one order of magnitude. (authors)
EDF nuclear waste management requires a deep understanding of characterization, classification and waste sorting operations. In fact, French nuclear waste management defines several classes with specific management, treatment and storage facilities. Based on particular criteria, the more the radiological risk of the nuclear waste is important, the more its management will be complex and expensive. During the dismantling of the first French pressurized reactor Chooz-A, decontamination of the primary water circuits (not including the reactor vessel), the steam generators and the pressurizer have been carried out in order to reduce their activity levels. Thanks to these decontamination operations, and a specific characterization methodology, EDF was able to de-classify the 4 steam generators and store them in one piece at the ANDRA Very Low Level Activity disposal facilities instead of the Low and Intermediate Level activity one. This de-classification allowed EDF to avoid important cutting and packaging processes. Therefore, significant dose reductions for the operators and financial gain have been made. To characterize and declare Chooz-A SG activity, EDF-CIDEN uses a methodology defined by the French institute of atomic energy, CEA. The method is based on external gamma spectrometry measurements performed with NaI collimated detectors, associated with MERCURAD simulations providing the transfer functions for the detectors and activity sources. Internal measurements are carried out with a CZT (CdZnTe) probe inside the SG tubes to refine the 3D model. In fact, the primary side represents the main source of activity, and understanding its contamination distribution is important to reduce the model and calculation uncertainties. Measurements eventually provide SG {sup 60}Co global activity, from which the activities of other radionuclides of the spectrum are determined using scaling factors. The final activity declaration takes into account the standard deviation of the measurements in order to cover the uncertainties of the methodology. Thereby, the declaration is 'slightly over-estimative', enough to meet the waste storage facility acceptance criteria. (authors)
Oxidation of zirconium and its alloys under any atmosphere is generally characterised by a protective and non-protective stage. During the protective stage, the kinetics of oxidation are quasi-parabolic, while the oxide scale formed on the surface of the metal is black, compact, and protective in nature. For the non-protective stage, the oxidation rate becomes linear, while the protective oxide film turns into a deteriorated white scale. Breakaway is known as the transition point from protective to non-protective stage. The actual mechanism leading to breakaway of zirconium is still a matter of controversy, however some of the most common factors affecting breakaway are the following: - Impurities on the metal (Carbon, Oxygen, Nitrogen); - Oxidizing atmosphere (Presence of H{sub 2}O (g) or N{sub 2} (g)); - Sample preparation (Chemically etched or polished); - Temperature (LWR, LOCA). This research investigates the effect of temperature on 'breakaway' when zirconium is oxidized isothermally in steam for 60 min at 800 and 900 deg. C using thermogravimetric and optical microscopic imaging techniques. 1. Steam isothermal oxidations were performed on zirconium at 800 and 900 deg. C using a Thermogravimetric Analyzer (TGA). 2. Log-log plots of mass gain vs time were obtained from thermogravimetric results to calculate the reaction orders (n) and reaction rate constants (K) during oxidation. 3. Results of the kinetics of reaction were correlated with optical microscopic images form Light Microscope (LM) and Scanning Electron Microscope (SEM). Breakaway depends very strongly on temperature. At 800 deg. C, the weight gain followed a cubic-parabolic behaviour with evidence of a protective oxide film. On the other hand, oxidation at 900 deg. C showed signs of breakaway since the oxide film was cracked and oxidation rate was almost linear throughout the reaction.
A model of a specific type of tube and shell heat exchanger, the helical coil steam generator (HCSG), was designed and constructed to study multiple fluidic properties that attribute to the efficiency of the heat transfer it provides. Tube and shell heat exchangers are currently used throughout industry in chemical, power and petroleum engineering. Most commonly, a primary flow is circulated through a shell, while the secondary flow is run through several small tubes that are bundled together. Methods to increase the heat transfer between the two flows include adding baffles to force shell side flow over more tubes, fins added in-between layers of tubes and passing tubes multiple times through the shell to increase heat exchanger effectiveness. The HCSG incorporates many of the proposed methods but also relies on a complex geometry to increase the heat transfer between tube and shell side flow. In an area where cost effectiveness is favorable, such as inside a nuclear reactor, helically banked steam generators makes extensive use of the room with no sharp tube bends. This increases the pressure loss on the secondary flow and can solve potential temperature manufacturing issues at the welds of junctions. Additionally, they have exhibited pure cross flow behaviors with high heat transfer coefficients and axial temperature profiles that correspond to pure counter-flow with high mean temperature differences. Early work showed that helical banks can have a significant increase of 16 to 43% higher heat transfer coefficient than straight pipe heat exchangers. While many previous studies have looked at the heat transfer, pressure drop and flow fields of a tube and shell heat exchanger, they all focus on tube bundles that are either in-line or staggered. The early flow visualization studies on these types of bundle arrangements reported that attached eddies were formed alternatively behind each of the rods and were occasionally dragged into the main stream of shell side flow. Later studies suggested that observable periodic vortex shedding was dependent on geometry. Experimental data taken using techniques such as laser Doppler anemometry (LDV) by Simonin and Barcouda (1986) as mentioned in Hassan (2002), hot-wire anemometry with Tsuchida (1982) and particle image velocimetry (PIV) conducted by researchers as late as 2007 have been used to characterize turbulent flow and distinguish flow field structures within in-line and staggered tube bundles. By studying these flow field structures, their contribution to fluidic properties such as heat transfer efficiency and pressure drop can be characterized effectively. Literature review lead to a design that incorporated five layers of coils wrapped around one another. The outermost and middle layers of tubes coiled at a specific pitch in a clockwise direction while the other two layers coiled counterclockwise. The proposed design incorporates a constantly changing lateral pitch ratio, a, between adjacent rods. The constructed test section isolates a single interface between two adjacent coiling rod bundles of twelve rods. Three distinct cross sectional planes along the rod bundles were looked at to study the effect of the local geometry to flow fields, Section A, B and C. Particle Image Velocimetry (PIV) frames of 896 x 848 pixels were captured at each section across a specific height. Profiles of mean velocity fields for each section are compared and discussed as possible features of the changing lateral pitch ratio.
Two-phase flow instability is a critical area to consider in the design of steam generators. Oscillation of the flow rate and the system pressure caused by heating may cause several problems and is unfavorable in an extreme case because it causes a burnout of the heat transfer surface. A large amplitude variation in the heat transfer tube wall temperature generally occurs under density wave oscillation (DWO) conditions, and a continuous cycling tube wall temperature may lead to damage to the tube, causing thermal fatigue problems. Therefore, instability of the flow should be avoided, and a two-phase flow system should be designed to have a sufficient margin to avoid this. A computer program was developed for predicting a two-phase flow instability in a steam generator heated by liquid sodium, and the results of numerical studies for several parameters are presented in this paper.
This study focuses on design parameter sensitivity studies pertaining to a steam generator (SG) model, using both Python and machine-learning tools. The SG model is a mathematical representation (including fluid flow and heat transfer equations/models/correlations) of a steam-generating unit in a pressurized water reactor (PWR)-type small modular reactor (SMR) system. Design studies involve changing the model’s input design parameters (e.g., temperature, pressure, mass flow rate) to observe the resulting effects on the output of the system (e.g., heat transfer coefficient [HTC], Nusselt number, heat transfer performance). Sensitivity studies analyze the degree to which system output and/or desired parameters (e.g., HTC or heat transfer performance) are sensitive to changes in input parameters. By using machine-learning tools such as the Risk Analysis Virtual Environment (RAVEN) developed at Idaho National Laboratory (INL), detailed design parametric sensitivity studies and model optimization were performed. Six input parameters—namely, the pressure, temperature, and mass flow rate for the inlet of the primary-side (hot fluid) and secondary-side (cold fluid) of the SG—were randomly perturbed via RAVEN’s Monte Carlo Sampler module, using uniform distributions (±1% relative changes). The analysis results give valuable insights into SG system performance and optimization, and provide justification for researching optimized sensor placement to effectively monitor and obtain experimental data.
This study focuses on design parameter sensitivity studies pertaining to a steam generator (SG) model, using both Python and machine-learning tools. The SG model is a mathematical representation (including fluid flow and heat transfer equations/models/correlations) of a steam-generating unit in a pressurized water reactor (PWR)-type small modular reactor (SMR) system. Design studies involve changing the model’s input design parameters (e.g., temperature, pressure, mass flow rate) to observe the resulting effects on the output of the system (e.g., heat transfer coefficient [HTC], Nusselt number, heat transfer performance). Sensitivity studies analyze the degree to which system output and/or desired parameters (e.g., HTC or heat transfer performance) are sensitive to changes in input parameters. By using machine-learning tools such as the Risk Analysis Virtual Environment (RAVEN) developed at Idaho National Laboratory (INL), detailed design parametric sensitivity studies and model optimization were performed. Six input parameters—namely, the pressure, temperature, and mass flow rate for the inlet of the primary-side (hot fluid) and secondary-side (cold fluid) of the SG—were randomly perturbed via RAVEN’s Monte Carlo Sampler module, using uniform distributions (±1% relative changes). The analysis results give valuable insights into SG system performance and optimization, and provide justification for researching optimized sensor placement to effectively monitor and obtain experimental data.
Older heating systems often suffer from mis-investment--multiple contractors upgrading parts of systems in inadequate or inappropriate ways that reduce system functionality and efficiency--or from a lack of proper maintenance. This technical report addresses these barriers to information, contractor resources, and cost-savings. Building off of previous research, CNT Energy conducted a study to identify best practices for the methodology, typical costs, and energy savings associated with steam system balancing.
Improving Steam System Performance: A Sourcebook for Industry was developed for the U.S. Department of Energy's (DOE) Advanced Manufacturing Office (AMO), formerly the Industrial Technologies Program. AMO undertook this project as a series of sourcebook publications. Other topics in this series include: compressed air systems, pumping systems, fan systems, process heating and motor and drivesystems. For more information about program resources, see AMO in the Where to Find Help section of this publication.
Abstract Commonly used methods to assess crystallinity, micro‐/mesoporosity, Brønsted acid site density and distribution (in micro‐ vs. mesopores), and catalytic activity suggest nearly invariant structure and function for aluminosilicate zeolite MFI two‐dimensional nanosheets before and after superheated steam treatment. Yet, pronounced reaction rate decrease for benzyl alcohol alkylation with mesitylene, a reaction that cannot take place in the zeolite micropores, is observed. Transmission electron microscopy images reveal pronounced changes in nanosheet thickness, aspect ratio and roughness indicating that nanosheet coarsening and the associated changes in the external (mesoporous) surface structure are responsible for the changes in the external surface catalytic activity. Superheated steam treatment of hierarchical zeolites can be used to alter nanosheet morphology and regulate external surface catalytic activity while preserving micro‐ and mesoporosity, and micropore reaction rates.
This work deals with the production of ethanol from phosphoric acid-impregnated, steam-exploded Eucalyptus benthamii. The whole conversion process, addressing pretreatment, enzymatic hydrolysis of the whole slurry, and fermentation of both C5 and C6-sugars including a presaccharification step, is covered in this study. This work deals with the production of ethanol from phosphoric acid-impregnated, steam-exploded Eucalyptus benthamii. The whole conversion process, addressing pretreatment, enzymatic hydrolysis of the whole slurry, and fermentation of both C5 and C6-sugars including a presaccharification step, is covered in this study. Two separate models were developed to maximize sugar content and minimize inhibitor concentrations, resulting in xylose yields of ~50% and ~60% after pretreatment. In addition, a Liquefaction plus Simultaneous Saccharification and co-Fermentation (L+SScF) was performed to compare the fermentability of the resulting pretreated biomass. After the 6-h liquefaction step using the Cellic CTec2 enzyme from Novozyme and 10% DW pretreated biomass, the total sugar concentration in the slurry was 47 g/L and 51 g/L for the two conditions respectively. Enzymatic hydrolysis continued during fermentation using an ethanologenic derivative of Escherichia coli KO11. Here, the sugars were completely consumed in 96 h with product yields of 0.217 and 0.243 g ethanol/g DW biomass for each condition, respectively. Furthermore, these yields are equivalent to 275 and 304 L/tonne DW, confirming the effectiveness of the L+SScF process using phosphoric-acid-pretreated Eucalyptus.
Terry steam turbines are employed in the safety systems of many nuclear Boiling Water Reactors to drive pumps and provide cooling water to the nuclear reactor core. While the turbine efficiency is low, the more important feature is high reliability under off-normal conditions. An important aspect of reliability is the ability to function with two-phase steam-water injection into the turbine, as most likely occurred in the Fukushima Dai-ichi nuclear accidents. This study investigates the characteristics of a Terry turbine during air-water injection with gas mass fractions ranging from 1 (dry gas) to 0.05 (wet gas), to better understand the Terry turbine’s true operational capabilities and provide justification for extended Terry turbine use for reactor safety. Other parameters investigated are the inlet pressure, the exhaust backpressure and the turbine’s rotational speed. The turbine performance is presented in terms of dynamometer loading and pump performance change as functions of the gas mass fraction.
The 1-bar steam oxidation behavior of Ni-base superalloys 690, 725, and X-750 was evaluated at 600 and 650 °C for up to 5000 h. In addition to monitoring mass changes, microstructures of the 5000-h-exposed samples were characterized using scanning and transmission electron microscopy and energy dispersive x-ray spectroscopy. Together with thermodynamic calculations, the scale constitution and possible exfoliation was discussed. Alloy X-750 exhibited the best resistance to steam oxidation with the least metal thickness loss at 600 °C while alloy 690 at 650 °C. Alloy 725 exhibited more than two times metal thickness loss than the other two alloys at 650 °C.
Concentrating solar power plants can achieve low cost and efficient renewable electricity production if equipped with adequate thermal energy storage systems. Metal hydride based thermal energy storage systems are appealing candidates due to their demonstrated potential for very high volumetric energy densities, high exergetic efficiencies, and low costs. The feasibility and performance of a thermal energy storage system based on NaMgH 2 F hydride paired with TiCr 1.6 Mn 0.2 is examined, discussing its integration with a solar-driven ultra-supercritical steam power plant. The simulated storage system is based on a laboratory-scale experimental apparatus. It is analyzed using a detailed transport model accounting for the thermochemical hydrogen absorption and desorption reactions, including kinetics expressions adequate for the current metal hydride system. The results show that the proposed metal hydride pair can suitably be integrated with a high temperature steam power plant. The thermal energy storage system achieves output energy densities of 226 kWh/m 3 , 9 times the DOE SunShot target, with moderate temperature and pressure swings. Also, simulations indicate that there is significant scope for performance improvement via heat-transfer enhancement strategies.
Recent interest in U 3 Si 2 as an advanced light water reactor fuel has driven assessment of numerous properties, but characterization of its response to H 2 O environments is absent from the literature. The behavior of U 3 Si 2 in H 2 O containing atmospheres is investigated and presented in a two-part series of articles aimed to understand the degradation mechanism of U 3 Si 2 in H 2 O. Reported here are thermogravimetric data for U 3 Si 2 exposed to flowing steam at 250–470 °C. Additionally the response of U 3 Si 2 to flowing Ar-6% H 2 from 350 to 400 °C is presented. Microstructural degradation is observed following hours of exposure at 350 °C in steam. U 3 Si 2 undergoes pulverization on the timescale of minutes when temperatures are increased above 400 °C. In conclusion, this mechanism is accelerated in flowing Ar-H 2 at the same temperatures.