Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “computation fluid dynamic modeling”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 469 records · Page 26

Laser-Induced Thermal Acoustics Theory and Expected Experimental Errors when Applied to a Scramjet Isolator Model

A scramjet isolator model test apparatus is being assembled in the Isolator Dynamics Research Lab (IDRL) at the NASA Langley Research Center in Hampton, Virginia. The test apparatus is designed to support multiple measurement techniques for investigating the flow field in a scramjet isolator model. The test section is 1-inch high by 2-inch wide by 24-inch long and simulates a scramjet isolator with an aspect ratio of two. Unheated, dry air at a constant stagnation pressure and temperature is delivered to the isolator test section through a Mach 2.5 planar nozzle. The isolator test section is mechanically back-pressured to contain the resulting shock train within the 24-inch isolator length and supports temperature, static pressure, and high frequency pressure measurements at the wall. Additionally, nonintrusive methods including laser-induced thermal acoustics (LITA), spontaneous Raman scattering, particle image velocimetry, and schlieren imaging are being incorporated to measure off-wall fluid dynamic, thermodynamic, and transport properties of the flow field. Interchangeable glass and metallic sidewalls and optical access appendages permit making multiple measurements simultaneously. The measurements will be used to calibrate computational fluid dynamics turbulence models and characterize the back-pressured flow of a scramjet isolator. This paper describes the test apparatus, including the optical access appendages; the physics of the LITA method; and estimates of LITA measurement uncertainty for measurements of the speed of sound and temperature.

Middleton, Troy F.↗

Using RotCFD to Predict Isolated XV-15 Rotor Performance

Experimental techniques to measure rotorcraft aerodynamic performance are widely used. However, the need exists to understand the limitations of ground based testing by augmenting the analysis of experimental test results with Computational Fluid Dynamics (CFD) modeling. The immediate objective of the present research is to develop an XV-15 Tilt Rotor Research Aircraft rotor model for investigation of wind tunnel wall interference. The predicted performance of the XV-15 during various flight modes is compared to theoretical and experimental data. This research is performed to support wind tunnel tests scheduled for 2016. A mid-fidelity RANS solver, RotCFD, is used with an unsteady, incompressible flow model and a realizable k- turbulence model. The rotor is modeled using an actuator disk model or blade element model with a momentum source approach. In RotCFD the setup, grid generation and running of cases is faster than many CFD codes which makes it a useful engineering tool. Performance predictions need not be as accurate as high-fidelity CFD codes, as long as wall effects can be properly simulated. Being able to accurately predict unsteady rotorcraft performance on desktop-class computers provides a quicker analysis of highly complex flows during the initial design phase.

CFD↗

Time-Accurate Computational Fluid Dynamics Analysis of a Supersonic Turbine to Assess Structural Mode Excitation

Gas turbines can experience significant unsteady loading during operation which can cause damage such as blade cracking or bearing wear. While computational fluid dynamics (CFD) modeling of full three-dimensional gas turbine flow to verify meanline design performance is standard practice within the industry, the use of time-accurate CFD makes it possible to assess the unsteady loading which can be especially problematic at operating conditions where unsteady fluid loading aligns with structural modes. The Fluid Dynamics branch (ER42) at NASA Marshall Space Flight Center has developed a time-accurate CFD analysis methodology using the unstructured, density-based, Loci-CHEM solver which is capable of simulating the relative motion required for turbomachinery applications through sliding interface meshes. The highly-parallel unstructured solver allows for full three-dimensional, time-accurate simulation of turbines including upstream and downstream components such as manifolds, nozzles, and stators, any of which could excite a turbine structural mode. Recently, Loci-CHEM was used to analyze the FASTRAC supersonic turbine to assess the loading on the rotor. Overall performance and time-averaged loading on the rotor was computed, including the axial force over the entire rotor disk which is required for force balance calculations on the turbopump. The FASTRAC turbine has supersonic nozzles upstream of the rotor that result in significant unsteady loading on the rotor blades at multiples of the nozzle pass frequency. The unsteady blade pressure loading was decomposed into the frequency domain for direct use in structural forced response analysis. Utilizing this type of CFD analysis coupled with structural analysis has proven to be a valuable tool in identifying structural modes that are being excited by unsteady fluid loading.

M.V. Fischels↗

Time-Accurate Computational Fluid Dynamics Analysis of a Supersonic Turbine to Assess Structural Mode Excitation

Gas turbines can experience significant unsteady loading during operation which can cause damage such as blade cracking or bearing wear. While computational fluid dynamics (CFD) modeling of full three-dimensional gas turbine flow to verify meanline design performance is standard practice within the industry, the use of time-accurate CFD makes it possible to assess the unsteady loading which can be especially problematic at operating conditions where unsteady fluid loading aligns with structural modes. The Fluid Dynamics branch (ER42) at NASA Marshall Space Flight Center has developed a time-accurate CFD analysis methodology using the unstructured, density-based, Loci-CHEM solver which is capable of simulating the relative motion required for turbomachinery applications through sliding interface meshes. The highly-parallel unstructured solver allows for full three-dimensional, time-accurate simulation of turbines including upstream and downstream components such as manifolds, nozzles, and stators, any of which could excite a turbine structural mode. Recently, Loci-CHEM was used to analyze the FASTRAC supersonic turbine to assess the loading on the rotor. Overall performance and time-averaged loading on the rotor was computed, including the axial force over the entire rotor disk which is required for force balance calculations on the turbopump. The FASTRAC turbine has supersonic nozzles upstream of the rotor that result in significant unsteady loading on the rotor blades at multiples of the nozzle pass frequency. The unsteady blade pressure loading was decomposed into the frequency domain for direct use in structural forced response analysis. Utilizing this type of CFD analysis coupled with structural analysis has proven to be a valuable tool in identifying structural modes that are being excited by unsteady fluid loading.

M V Fischels↗

CFD Modeling & Validation of Single Bubble Growth During Cavitation in Zero Gravity

Cryogenic Fluid Management (CFM) in zero gravity represents a vital area of research as NASA pursues future long-duration space missions. Success of these missions relies heavily on the ability to store and transfer the cryogenic liquid fuels efficiently and safely. In the Zero Boil-Off Tank (ZBOT-1) Experiment in 2018, unexpected and intense phase change occurred at the screened Liquid Acquisition Device (LAD) during tank pressure control that was later attributed to cavitation. The cavitation ultimately resulted in pump failure. Since cryogen cavitation during storage and transfer of propellants in microgravity has been a source of serious concern for the aerospace community, a series of drop tower experiments with liquid methane were also performed at the University of Bremen to carefully study cavitation from a single bubble nucleus in an engineered micron-sized wall cavity. As the test cell is depressurized during the 10-second drop, cavitation causes bubble growth from the nucleus. Here, in a collaboration between the Case Western Reserve University and University of Bremen, we present a two-phase Computational Fluid Dynamics (CFD) model of bubble growth from a single wall cavity during depressurization in microgravity. Both 2D axisymmetric and 3D parametric simulation case studies are performed to show the evolution of the bubble growth. The model uses a Volume of Fluid (VOF) approach with and without adaptive mesh refinement and adaptive time stepping to capture the growth dynamics using an explicit formulation with algebraic reconstruction of the interface. CFD results show good agreement with corresponding experiment. Based on the velocity, temperature, and volume fraction fields generated by the validation case studies, detailed discussion and analysis of fluid flow and heat transfer during bubble growth process are presented to delineate the intricacies of the cavitation process. Strengths and shortcomings of the present numerical approach in capturing this phenomenon are also highlighted.

Two Phase Flow↗

MULTI-DIMENSIONAL MODELING OF THE CFR ENGINE FOR THE INVESTIGATION OF SI NATURAL GAS COMBUSTION AND CONTROLLED END-GAS AUTOIGNITION

Engine knock and misfire are barriers to pathways leading to high-efficiency Spark-Ignited (SI) Natural Gas engines. The general tendency to knock is highly dependent on engine operating conditions and the fuel reactivity. The problem is further complicated by low emission limits and the wide range of chemical reactivity in pipeline quality natural gas. Depending on the region and the source of the natural gas, its reactivity, described by its methane number (analogous to the octane number for liquid SI fuels) can span from 65 - 95. In order to realize diesel-like efficiencies, SI natural gas engines must be designed to operate at high BMEP near knock limits over a wide range of fuel reactivity. This requires a deep understanding regarding the combustion-engine interactions pertaining to flame propagation and end-gas autoignition (EGAI). However, EGAI, if controlled, provides an opportunity to increase SI natural gas engine efficiency by increasing combustion rate and the total burned fuel, mitigating the effects of the slow flame speeds of natural gas fuels which generally reduce BMEP and increase unburned hydrocarbon emissions. For this reason, in order to study EGAI phenomenon, the present work highlights multi-dimensional computational fluid dynamics (CFD) models of the Cooperative Fuel Research (CFR) engine. The CFR engine models are used to investigate fuel-engine interactions that lead to EGAI with natural gas, including effects of fuel reactivity, engine operating parameters, and exhaust gas recirculation (EGR). A Three-Pressure Analysis, performed with GT-Power, was used to estimate initial and boundary conditions for the three-dimensional CFD model. CONVERGE CFD v2.4 was used for the three-dimensional CFD modeling where the level set G-Equation model and SAGE detailed chemical kinetics solver were used. An assessment of the different modeling approaches is also provided to evaluate their limitations, advantages and disadvantages, and for which situations they are most applicable. Model validation was performed with experimental data taken with a CFR engine over varying compression ratio, CA50, EGR fraction, and IMEP and shows good agreement in Peak Cylinder Pressure (PCP), PCP crank angle, and the location of the 10%, 50%, and 90% mass fraction burned (CA10, CA50, and CA90, respectively). The models can predict the onset crank angle and pressure rise rate for light, medium, and heavy EGAI under a variety of fuel reactivities and engine operating conditions.

Bestel, Diego↗

An Efficient Three-Dimensional CFD-Based Numerical Wave Tank for a Wave Energy Converter in Extreme Irregular Waves: Preprint

A numerical wave tank approach for computational fluid dynamics (CFD) modelling of an extreme irregular seastate is presented. The technique couples a potential flow solution with a CFD solver for more efficient numerical predictions. This method has recently become attractive both for the research community and the industry working with offshore structures. The model is used to determine the response of a submerged pressure differential wave energy converter (WEC) in a fully nonlinear irregular wave condition using the high fidelity CFD code, STAR-CCM+. Potential flow based numerical models are commonly used to predict motions and performance of wave energy converters. Wave kinematics can deviate from potential flow predictions for extreme wave conditions; the excitation loads on an absorber can also be increasingly influenced by viscous effects, not captured in engineering level models. In these extreme conditions, a Reynolds-averaged Navier-Stokes CFD model can better predict motions and loads for a WEC. Long time series with varying random seed numbers can be used to identify singular extreme wave events from a stochastic irregular sea state. This approach simulates a more realistic wave series for a given sea state than a regular wave or a focused wave. However, it is computationally infeasible to run these long time series for three-dimensional (3D) CFD simulations. In this work, two-dimensional (2D) CFD simulations with a long domain allow the full development of an extreme nonlinear wave condition. The results are used to identify extreme events from a 50-year storm condition for the PacWave site off the coast of Oregon. A relatively short time window including this extreme event is then mapped to a 3D simulation using a user defined wave methodology. Convergence studies for domain length, wave forcing lengths, and time before the extreme event were conducted.

cfd↗

Overview of Mars Sample Return – Earth Entry System Woven Roughness Heating Augmentation Test in NASA Langley’s Mach 6 Wind Tunnel

The Mars Sample Return Mission (MSR) is a planned NASA flagship mission in which a sample retrieval lander (SRL) with a rover will be flown to Mars to obtain sample tubes on the surface that were dropped by the Mars 2020 rover [1]. After obtaining the sam-ples, the rover will return and ascend back to Martian orbit onboard the Mars Ascent Vehicle (MAV). Upon return to Earth orbit, the samples will perform Entry, Descent, and Landing (EDL) with the Earth Entry Sys-tem (EES) architecture, and land in Utah. The EES vehicle will utilize a HEEET-variant as its TPS, which will be the first time a woven TPS will be used on a flagship NASA mission [2]. This TPS offers a unique challenge for Computational Fluid Dynamics (CFD) modeling of the aerothermal envi-ronment of the vehicle, as woven roughness heating augmentation has not been extensively investigated experimentally. As a result, in order to validate com-putational models for woven roughness heating aug-mentation, a wind tunnel test campaign at NASA Langley Research Center’s Mach 6 wind tunnel was performed in April of 2023. This test campaign consisted of over a hundred runs with Reynolds numbers spanning from 1-7 mil-lion 1/ft and with six separate wind tunnel models used. A second campaign with a suite of new models will be conducted in Summer 2023 as well as a cam-paign with a flat plate model, both of which are of great interest to the MSR-EES project. The data obtained from this test are extremely vital for the MSR mission, as they will validate CFD roughness heating models which will be directly used to design the TPS of the EES portion of MSR and characterize the heating environment that the entry ve-hicle will experience. Further extensions of the MSR-EES test campaign will continue to provide validation data for developing more effective computational tools.

Jonathan Cheatwood↗

Microfabrication of a Segmented-Involute-Foil Regenerator, Testing in a Sunpower Stirling Convertor and Supporting Modeling and Analysis

Under Phase II of a NASA Research Award contract, a prototype nickel segmented-involute-foil regenerator was microfabricated via LiGA and tested in the NASA/Sunpower oscillating-flow test rig. The resulting figure-of-merit was about twice that of the approx.90% porosity random-fiber material currently used in the small 50-100 W Stirling engines recently manufactured for NASA. That work was reported at the 2007 International Energy Conversion Engineering Conference in St. Louis, was also published as a NASA report, NASA/TM-2007-2149731, and has been more completely described in a recent NASA Contractor Report, NASA/CR-2007-2150062. Under a scaled-back version of the original Phase III plan, a new nickel segmentedinvolute- foil regenerator was microfabricated and has been tested in a Sunpower Frequency-Test-Bed (FTB) Stirling convertor. Testing in the FTB convertor produced about the same efficiency as testing with the original random-fiber regenerator. But the high thermal conductivity of the prototype nickel regenerator was responsible for a significant performance degradation. An efficiency improvement (by a 1.04 factor, according to computer predictions) could have been achieved if the regenerator been made from a low-conductivity material. Also the FTB convertor was not reoptimized to take full advantage of the microfabricated regenerator's low flow resistance; thus the efficiency would likely have been even higher had the FTB been completely reoptimized. This report discusses the regenerator microfabrication process, testing of the regenerator in the Stirling FTB convertor, and the supporting analysis. Results of the pre-test computational fluid dynamics (CFD) modeling of the effects of the regenerator-test-configuration diffusers (located at each end of the regenerator) is included. The report also includes recommendations for accomplishing further development of involute-foil regenerators from a higher-temperature material than nickel.

Ibrahim, Mounir B.↗

Seawater Acidification and Bubble Plume Dispersion from Accidental Subsea CO 2 Pipeline Rupture: A Multiphase CFD Study

If a CO 2 reservoir or transmission pipeline were to leak, both the surrounding ecology and maritime traffic safety could be put at risk. To better understand and prepare for this risk, multiphase Computational Fluid Dynamics (CFD) models were built in ANSYS Fluent to capture the behavior of a leak once it enters the water. A 3D Eulerian–Eulerian model was used for validation, while a simplified 2D model was applied to simulate conditions at a 50-m depth. The models integrate bubble dynamics, gas holdup, CO 2 dissolution, dissolved species transport, and seawater acidification into a unified CFD framework. Mass transfer was calculated using the Hughmark correlation, and local seawater temperature and salinity were factored in to determine dissociation behavior and the relevant Henry’s Law constant. To confirm the 3D model’s accuracy, results were checked against two experimental datasets: the QICS field study and the Hauser Tank experiments. The team also modeled a hypothetical release scenario at the High Island 10L site and compared the results with earlier published work. The results show that at a depth of 50 m, the surrounding water column can completely absorb a CO 2 release at a rate of 35 kg/s, since the gas dissolves into the seawater as it rises toward the surface. Beyond confirming this mitigation capacity, the simulations shed light on how a leak would actually unfold in the environment, including the shape and movement of the rising bubble plume, how much CO 2 dissolves along the way, and the resulting shifts in seawater pH and pCO 2 . Together, this provides a practical framework for assessing how CO 2 leaks could affect marine environments in the Gulf of Mexico.

54 ENVIRONMENTAL SCIENCES↗

An index to characterize gas‐solid and solid‐solid mixing from average volume fraction fields

Abstract A mixing index based on solid volume fraction fields is developed for gas‐solid flows. Conventional mixing indices are based on particle realizations of granular mixing and are applicable to experimental data or discrete element method simulations. However, these indices cannot be used as‐is for multifluid models, and an index for characterizing mixing in gas‐solid flows from continuous fields is needed. The performance of the new mixing index is tested in two applications. The first is a 3D simulation of the mixing of biomass and sand in a fluidized bed reactor, and the second is a 2D simulation of binary particle segregation in a fluidized bed. The simulations are performed using OpenFOAM®. The mixing index is used to quantify gas‐solid mixing using solid volume fractions and solid‐solid mixing using solid fractions. The formulation of conventional mixing indices is extended to be used with solid volume fractions fields, and methods for performance improvement are presented.

09 BIOMASS FUELS↗

Representative Phenomena of Cyclic Turbulent Combustion in High-Pressure Fuel Sprays

Abstract Cyclic variations in conventional diesel combustion engines can lead to large differences in engine out emissions even at steady operation. This study uses an optically accessible constant-pressure flow chamber to acquire fuel injections in quick succession to analyze mixing, auto-ignition, and combustion of diesel-surrogate n-heptane using multiple high-speed optical diagnostics. Prior studies have utilized fewer injections and/or they rely on analysis of ensemble average behavior. These approaches do not yield information on injection-to-injection variation or provide confidence in utilizing individual injection measurements for high-fidelity computational fluid dynamics(CFD) model validation. In this study, a large set of 500 injections is used to obtain global parameters including liquid length, vapor penetration length, ignition delay time, and lift-off length. Results for multiple injections are presented to illustrate large injection to injection variations. Potential sources for these variations are analyzed to conclude localized, small scale turbulence and rate of injection variations as the likely sources. Then, a statistical method based on z-scores is proposed and implemented to identify instantaneous injections that best represent the bulk data-set of jet boundaries measured independently by three different diagnostics. This synthesis of statistics-guided screening of data set and ensemble-average analysis offers higher confidence for CFD model validation relying upon both a representative single and average injection results.

42 ENGINEERING↗

A Large Eddy Simulation Study of Flow Turbulence, Alumina Transport, and Bath Temperature Evolution in Conventional Aluminum-Smelting Cell Using OpenFOAM

In this study, a Large Eddy Simulation (LES) of the aluminum-smelting process is performed using OpenFOAM. To understand the coupled behavior of heat transfer, mass transfer, and flow of the smelting process, a multi-physics computational fluid dynamics (CFD) model based on the Eulerian–Eulerian multi-fluid approach is adopted. The model accounts for CO 2 bubble and magnetohydrodynamics (MHD)-driven flow, along with alumina dissolution, transport, and bath temperature evolution. The simulation predictions show small-scale turbulent vortical structures in the anode–cathode space caused by combined effect of MHD and CO 2 bubble-bath interactions and relatively large-scale asymmetric vortices in the inter-anode space caused by the CO 2 bubble-bath interactions. The vortex formation at the edges of the anodes evidently aids in transporting alumina from the central channel to the bottom of the anodes and prevents accumulation of gas bubbles in the periphery of the anode bottom. Symmetric bath cold spots are observed in the vicinity of the feeder. Cold spots are also observed in the anode–cathode distance space below the anode bottom due to the transport of undissolved solid to this region by the flow. The findings from the work are useful in developing and designing alumina-feeding strategy leading to reduced anode effects and smooth operation of the cell. The work also highlights the important flow structures in conventional aluminum-smelting cell.

36 MATERIALS SCIENCE↗

CFD Simulation of Floating Body Motion with Mooring Dynamics: Coupling MoorDyn with OpenFOAM

It is increasingly popular to use Computational Fluid Dynamics (CFD) models to study floating structures subjected to ocean waves, especially when it comes to applications of floating offshore wind turbines and Wave Energy Converters (WECs). Mooring dynamics are currently lacking in most of these applications. This paper presents a coupled simulation study of moored floating body motion by coupling two open-source libraries: a finite volume CFD toolbox, OpenFOAM, and a lumped-mass mooring model, MoorDyn. The instantaneous floating body position and velocity are passed from the body motion solver in the CFD model to the mooring model to calculate the fairlead kinematics. The mooring reaction forces, which are calculated by MoorDyn after updating the mooring system states, are then returned to the body motion solver to update the floating body motion. Both mesh deformation and overset mesh methods are used as the mesh motion solver in the CFD model to account for the floating body motion. The coupled model was validated against experimental measurements for a floating box moored with four catenary lines under the action of regular waves, which came from a preliminary test campaign for WECs. Apart from the lumped-mass mooring model, the present work also coupled a quasi-static mooring model and a finite element model with the floating body motion solver in OpenFOAM. The mooring line tensions predicted by these models were compared. The coupled model equipped with three mooring line codes may be further used to carry out survivability studies of FOWTs and WECs subject to severe sea states.

floating body↗

Computational studies of impurity migration during induction stirring of molten uranium

Understanding and controlling impurity behavior in actinide metal casting processes are foundational for efficient part production yet remain major challenges for researchers and industry. To help provide insight regarding impurity distribution during actinide metal casting, we have developed computational fluid dynamics (CFD) models for a laboratory-scale system using commercial and open-source code. Multiple simulation frameworks allow for improved confidence in the resulting outputs, while taking advantage of the maturity and convenience offered by commercial platforms and simultaneously maintaining the transparency and flexibility often provided by open-source software. Here, we describe multiple experiment-informed models designed to simulate a specific laboratory system in which uranium melt, containing a known starting concentration of carbon impurity, is electromagnetically stirred in an induction furnace. Here, the goal of the simulations is to predict the motion of uranium carbide microparticles in the velocity field of the melt. Prior to simulating the uranium-carbon system, numerical models were validated using a previously published nonradioactive experimental system. Effects of the size and shape of impurity particles in the models were investigated and agree with experimental findings. Simulation of smaller particles (< 50 µm) shows more homogenous distribution throughout the stirred melt. With increased particle size (100 µm), the body forces, which include the buoyancy force, dominate over the drag force, causing larger particles to move toward the crucible walls and upward in the system.

36 MATERIALS SCIENCE↗

Estimation of the Thermal-Fluids and Thermal-Structural Performance of Helium-Cooled Modular Finger-Type Divertors

Over the past decade, our group has investigated the thermal-fluid performance of the helium-cooled modular divertor with multiple jets (HEMJ) and a simplified “flat” design of the HEMJ for long-pulse magnetic fusion energy (MFE) reactors. Experimental studies were performed in a helium (He) loop at the prototypical pressure of 10 MPa, nearly prototypical He temperatures and incident heat fluxes using test sections made from stainless steel and tungsten alloys. Correlations for average Nusselt numbers and pressure loss coefficients were developed from the data and are used to validate computational fluid dynamics (CFD) models. Here, this work presents updated thermal-fluids performance curves based on these correlations that estimate the maximum heat flux that can be accommodated by the plasma-facing surface and coolant pumping power requirements at prototypical operating conditions. Thermal-structural performance curves developed from ITER structural design criteria are introduced, which include protection against ductile and non-ductile failure, ratcheting fatigue, and creep fatigue. The performance design curves for these finger-type divertors demonstrate that the “flat” design, with a significantly less complicated geometry than the HEMJ, has thermal-fluid and thermal-structural performance comparable to the original HEMJ concept, and may be superior in terms of non-ductile failure criteria.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Oxygen enrichment combustion to reduce fossil energy consumption and emissions in hot rolling steel production

The reheating furnace operation in the hot mill is natural gas- and electricity-intensive. Oxygen enrichment combustion for reheating furnaces has been proposed to curb and replace natural gas use. In this study, heat transfer in steel slabs in the combustion environment of a push-type reheating furnace was simulated using a computational fluid dynamics (CFD) model. Two oxygen enrichment methods that optimized for performance were selected— a medium oxygen enrichment (MOE) case and an oxy-fuel (OF) case. A life cycle analysis (LCA) characterized the energy and emission profiles of an integrated iron and steel manufacturing process using the two oxygen enrichment cases for the hot mill. These conditions were evaluated for energy use and carbon intensity and compared with a baseline case. Results show that with oxygen enrichment, natural gas consumption can decrease by 19.6%–26.8%, total energy consumption (natural gas and electricity) can decrease by 15.1%–20.7% in the hot mill. Emissions of greenhouse gases can decrease by 11.1%–15.2% in the two optimized cases with 14%–27% reductions in regulated criteria pollutants (nitrogen oxides, carbon monoxide, particulate matter, volatile organic compounds, black carbon, organic carbon, and volatile organic carbons). There is a tradeoff between reducing natural gas consumption and increasing electricity demand from a life cycle perspective. Although the OF case resulted in higher energy- and emissions-related benefits, the MOE case showed the more desirable heat flux uniformity, which is key to maintaining product quality. The analysis suggests that oxygen enrichment in the reheating furnace process can have a significant impact on hot mill environmental performance and become a contributing factor in transitioning to low-carbon steel manufacturing.

36 MATERIALS SCIENCE↗

Margin to onset of nucleate boiling and flow instability studies for preliminary MITR design-demonstration element thermal-hydraulics

This study covers the onset of flow instability (OFI) preliminary results obtained from leveraging correlations, in addition to the preliminary thermal hydraulics results such as pressure, flow velocity, temperature, and oxide layer over the design demonstration experiment (DDE) for the Massachusetts Institute of Technology Reactor (MITR). Current computational fluid dynamics (CFD) models in fluid structure interaction (FSI) have added the capability of assessing margins to onset of nucleate boiling (ONB). This study initiates the capability to model the margin to OFI and ONB presented for the MITR. Such study is supportive of the United States High Performance Research Reactor (USHPRR) program. Previous studies provided preliminary thermal-hydraulic and mechanical analyses of the hydrodynamic effects in the MITR DDE under conservative approximations for plate power distribution. In conclusion, this study focuses on providing insights into the OFI future research direction optimizing the transport of thermal energy, mass-flow rates, flow-channel geometries, and boundary conditions.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗