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All sourcesNASA NTRSDOE OSTI
NASA NTRS2000

Exploiting the Temperature Dependence of Magnetic Susceptibility to Control Convection in Fundamental Studies of Solidification Phenomena

It is well known that convection is a dominant mass transport mechanism when materials are solidified on Earth's surface. This convection is caused by gradients in density (and therefore gravitational force) that are brought about by gradients in temperature, composition or both. Diffusion of solute is therefore dwarfed by convection and the study of fundamental parameters, such as dendrite tip shape and growth velocity in the absence of convection is nearly impossible. Significant experimental work has therefore been carried out in orbiting laboratories with the intent of minimizing convection by minimizing gravity. One of the best known experiments of this kind is the Isothermal Dendritic Growth Experiment (IDGE), supported by NASA. Naturally such experiments are costly and one objective of the present investigation is to develop an experimental method whereby convection can be- halted, in solidification and other experiments, on the surface. A second objective is to use the method to minimize convection resulting from the residual accelerations suffered by experiments in microgravity. The method to be used to minimize convection relies on the dependence of the magnetic susceptibility of a fluid on temperature or composition (whichever is driving convection). All materials experience a force when placed in a magnetic field gradient. The direction and magnitude of that force depend on the magnetic susceptibility of the material. Consequently the force will vary if the susceptibility varies with temperature or composition. With a magnetic field gradient in the right direction (typically upward) and of the right magnitude, this variation in the magnetic force can be made to exactly cancel the variation in the gravitational force. Expressed another way, normal buoyancy is exactly countered by a "magnetic buoyancy". To demonstrate the principle, a solution of MnC12 in water has been used. First the variation of the susceptibility of this paramagnetic solution with temperature and concentration was measured. Then a "cell", containing this solution and 50mm long by 15mm high by 155mm wide, was placed in a superconducting magnet at Marshall Space Flight Center. The magnetic field was measured at various positions within the bore of the magnet using a Hall effect probe. In this way, a position was found where the magnetic field gradient was predominantly upward; the magnitude of the gradient could then be adjusted by adjusting the current of the magnet. The ends of the cell consisted of machined copper blocks maintained at controlled temperatures by circulating water from constant temperature baths. The walls of the cell were of rectangular section glass tubing so that the cell contents could be seen. Velocities arising from thermal gradients within the cell were measured by particle image velocimetry (PIV). Particles used for this purpose were silver-coated hollow glass spheres of micrometers diameter and nearly the same density as the solution. A central vertical plane of the cell was illuminated by a laser beam passing through a cylindrical lens. Digital images of the particles were captured on a CCD camera and fed to a computer so that frame-to-frame movements of particles traveling with the fluid were captured. These images were employed to compute velocity maps using commercial PIV software. In a typical experiment the cold end of the cell was maintained at 10C and the warm end at 30 C. With no current in the magnet, i.e.- with natural -convection allowed to occur, the fluid was observed to circulate with an average speed of approximately 0.3 millimeters per second. It was visually apparent that this circulation was diminished as the current was increased. At currents of approximately 20A the flow was halted, to within the precision of the PIV measurements. At yet higher currents the convection was reversed with the hotter solution sinking and the cooler solution rising. At 40A this reversed convection had speeds averaging 0.43 millimeters per second. The measurements of susceptibility and density allow an estimate of the field gradient necessary to halt convection in the experiment. That estimate was 7.8T (squared) per meter and the convection was observed to halt in the magnet at a current giving 7.21T (squared) per meter from the magnetic field measurements. Calculations of the flow have been carried out using the computational fluid dynamics software FLUENT and show good agreement with the measurements.

Seybert, C. D.↗
DOE OSTI2012

Serpentine: Finite Difference Methods for Wave Propagation in Second Order Formulation

Wave propagation phenomena are important in many DOE applications such as nuclear explosion monitoring, geophysical exploration, estimating ground motion hazards and damage due to earthquakes, non-destructive testing, underground facilities detection, and acoustic noise propagation. There are also future applications that would benefit from simulating wave propagation, such as geothermal energy applications and monitoring sites for carbon storage via seismic reflection techniques. In acoustics and seismology, it is of great interest to increase the frequency bandwidth in simulations. In seismic exploration, greater frequency resolution enables shorter wave lengths to be included in the simulations, allowing for better resolution in the seismic imaging. In nuclear explosion monitoring, higher frequency seismic waves are essential for accurate discrimination between explosions and earthquakes. When simulating earthquake induced motion of large structures, such as nuclear power plants or dams, increased frequency resolution is essential for realistic damage predictions. Another example is simulations of micro-seismic activity near geothermal energy plants. Here, hydro-fracturing induces many small earthquakes and the time scale of each event is proportional to the square root of the moment magnitude. As a result, the motion is dominated by higher frequencies for smaller seismic events. The above wave propagation problems are all governed by systems of hyperbolic partial differential equations in second order differential form, i.e., they contain second order partial derivatives of the dependent variables. Our general research theme in this project has been to develop numerical methods that directly discretize the wave equations in second order differential form. The obvious advantage of working with hyperbolic systems in second order differential form, as opposed to rewriting them as first order hyperbolic systems, is that the number of differential equations in the second order system is significantly smaller. Another issue with re-writing a second order system into first order form is that compatibility conditions often must be imposed on the first order form. These (Saint-Venant) conditions ensure that the solution of the first order system also satisfies the original second order system. However, such conditions can be difficult to enforce on the discretized equations, without introducing additional modeling errors. This project has previously developed robust and memory efficient algorithms for wave propagation including effects of curved boundaries, heterogeneous isotropic, and viscoelastic materials. Partially supported by internal funding from Lawrence Livermore National Laboratory, many of these methods have been implemented in the open source software WPP, which is geared towards 3-D seismic wave propagation applications. This code has shown excellent scaling on up to 32,768 processors and has enabled seismic wave calculations with up to 26 Billion grid points. The WPP calculations have resulted in several publications in the field of computational seismology, e.g.. All of our current methods are second order accurate in both space and time. The benefits of higher order accurate schemes for wave propagation have been known for a long time, but have mostly been developed for first order hyperbolic systems. For second order hyperbolic systems, it has not been known how to make finite difference schemes stable with free surface boundary conditions, heterogeneous material properties, and curvilinear coordinates. The importance of higher order accurate methods is not necessarily to make the numerical solution more accurate, but to reduce the computational cost for obtaining a solution within an acceptable error tolerance. This is because the accuracy in the solution can always be improved by reducing the grid size h. However, in practice, the available computational resources might not be large enough to solve the problem with a low order method.

15 GEOTHERMAL ENERGY↗
DOE OSTI2012

Special Analysis of the Area 3 Radioactive Waste Management Site at the Nevada National Security Site, Nye County, Nevada

This report describes the methods and results of a special analysis (SA) of the Area 3 Radioactive Waste Management Site (RWMS) on the Nevada National Security Site (NNSS). The purpose of the SA is to determine if the approved performance assessment (PA) and composite analysis (CA) (Shott et al., 2001) remain valid. The Area 3 RWMS PA and CA were prepared as a single document and received conditional approval on October 6, 1999. A conditional Disposal Authorization Statement (DAS) for the Area 3 RWMS was issued on October 20, 1999. Since preparation of the approved PA and CA, new information and additional environmental monitoring data have been used to update the PA and CA. At the same time, continual advancements in computer processors and software have allowed improvement to the PA and CA models. Annual reviews of the PA and CA required by U.S. Department of Energy (DOE) Order DOE O 435.1 have documented multiple changes occurring since preparation of the PA and CA. Potentially important changes include: Development of a new and improved baseline PA and CA model implemented in the probabilistic GoldSim simulation platform. A significant increase in the waste inventory disposed at the site. Revision and updating of model parameters based on additional years of site monitoring data and new research and development results. Although changes have occurred, many important PA/CA issues remain unchanged, including the site conceptual model, important features, events, and processes, and the points of compliance. The SA is performed to document the current status of the PA/CA model and to quantitatively assess the impact of cumulative changes on the PA and CA results. The results of the SA are used to assess the validity of the approved PA/CA and make a determination if revision of the PA or CA is necessary. The SA was performed using the Area 3 RWMS, version 2.102, GoldSim model, the current baseline PA/CA model. Comparison of the maximum SA results with the PA performance objectives indicates that there continues to be a reasonable expectation of compliance. The resident exposure scenario was evaluated for compliance with the air pathway and all-pathways annual total effective dose (TED) performance objectives. The maximum mean air pathway TED, 7E-6 millisievert (mSv) at 1,000 years (y) has decreased relative to the approved PA and is significantly less than the 0.1 mSv limit. The maximum mean all-pathways annual TED, 7E-5 mSv at 1,000 y has increased but remains a small fraction of the 0.25 mSv limit. The SA maximum mean radon-222 (222Rn) flux density, 0.03 becquerel per square meter per second (Bq m-2 s-1), has increased relative to the PA results but is significantly less than the 0.74 Bq m-2 s-1 limit. The SA results continue to support a conclusion that the disposed waste inventory is protective of intruders and groundwater resources. The maximum mean intruder TED, 0.01 mSv for an acute construction scenario at the U-3ah/at disposal unit, was less than the 5 mSv performance measure. Site monitoring data and research results continue to support a conclusion that a groundwater pathway will not exist within the 1,000 y compliance period. Projected releases to the environment are a small fraction of the performance objectives. Cost-effective options for reducing releases further are unlikely to exist. Therefore, releases from the Area 3 RWMS are judged to be as low as reasonably achievable. Comparison of the maximum CA result with the 0.3 mSv CA dose constraint indicates that no action is required to reduce the dose from the Area 3 RWMS and all interacting sources of residual radioactive contamination. The SA maximum mean CA annual TED, 0.02 mSv at 1,000 y, has increased from the approved CA result but remains less than 10% of the dose constraint. The CA TED continues to be due predominantly to inhalation of plutonium-239 resuspended from soils contaminated by nuclear weapons tests conducted near the Area 3 RWMS. The SA results estimated with the Area 3 RWMS version 2.102 model indicate that changes to the PA and CA do not significantly alter the PA/CA results or conclusions. Although increases occur for the all-pathways annual TED, the 222Rn flux density, and the CA annual TED, all PA and CA results are a small fraction of the performance objectives or dose constraints. The same conclusion was reached for the approved PA and CA. The SA results continue to support a conclusion that there is a reasonable expectation of meeting all performance objectives and the CA dose constraint. There is no need to revise the DAS at this time. The SA results support a conclusion that the Area 3 RWMS PA and CA remain valid, and revision is not necessary at this time.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2019

First Annual Report on Pulsed Thermal Tomography Nondestructive Evaluation of Additively Manufactured Reactor Materials and Components: Pulsed Thermal Tomography Nondestructive Examination of Additively Manufactured Reactor Materials and Components

Additive manufacturing (AM, or 3D printing) for commercial nuclear energy applications is an emerging method for cost-efficient manufacturing aimed at replacing aging nuclear reactor parts and reducing costs for new construction. Because of the geometry of metallic structures of interest for nuclear applications, which consist of planar primitives with no symmetry of revolution, limited options are available for nondestructive evaluation (NDE), either during or post manufacturing. Known material flaws in AM include low-density regions consisting of non-sintered powder, which have to be detected to ensure the safety of long-term performance nuclear reactor components. As a solution to NDE of AM, we are developing pulsed thermal tomography (PTT) models and depth inversion algorithms for 3D imaging. PTT has many advantages because the method is non-contact and allows for in-service, NDE of AM nuclear reactor parts. By analyzing transients of surface temperature response due to internal thermal resistances, one can obtain 3D reconstructions of material effusivity using a unique inversion algorithm developed at Argonne. This report provides results of preliminary performance evaluation of PTT capability in detection of flaws in metallic structures, as well imaging complex geometry AM structures. Performance of PTT was investigated through modeling and experiments, Computer models of PTT were developed using COMSOL Heat Transfer module. Defects were modeled as cylindrical flat bottom holes (FBH), which is a common model of calibrated material flaws in thermal tomography experiments. Materials considered in this study include stainless steel 316 (SS316), stainless steel 304 (SS304), and Inconel 718. Theoretical analyses were conducted to validate inversion of simulated PTT data with COMSOL for a plate. Subsequently, 3D reconstructions were performed on COMSOL simulations for FBH, revealing a decrease in spatial resolution over depth due to thermal diffusion. The results of this study show that the performance of the inversion algorithm for detecting smaller defects depends strongly on the depth of the defect as well as the incident heat flux. The size of detectable defect was estimated by fitting a Gaussian function to surface temperature profile. The criteria for detectability was taken as 20mK noise equivalent temperature difference (NETD), which is currently the sensitivity limit of high-performance infrared cameras. It was determined through computer simulations that the smallest detectable FBH in SS316 has a 50µm diameter and is located 0.5mm below the plate surface. Preliminary experimental studies were performed to evaluate PTT performance in detecting calibrated flaws using metallic specimens with AM defects simulated as drilled-in FBH’s. High strength Stainless Steel 316 and Inconel 718 alloys were considered, as well as lower grade Stainless Steel 304, Nickel 200, and Hastelloy C276. Specimens investigated in this report consisted of approximately 1/4in-thick plates made out of these alloys using conventional manufacturing methods. The diameters of FBH’s varied from 1mm to 8mm, and their depths below the plate flat surface varied between 1mm and 6mm. The size of the smallest FBH was limited to 1mm because conventional mechanical drills were used for creating the holes. PTT imaging results have shown that 1mm-diameter FBH located 1mm and 2mm below the surface were detectable. Larger size FBH were detectable at greater depth. For example, 6mm-diameter FBH could be detected at 8mm depth. Image contrast varied slightly between the specimens, with the best reconstructions obtained in SS316 and C276 plates. Finally, PTT capability in imaging several AM structures fabricated from Inconel 718 (IN718) powder feedstock was investigated. The AM structures have complex geometry, but do not have calibrated internal defects. The objective is to determine PTT settings, such as the total integration time, for imaging of representative AM structures. A new FLIR X8500sc IR camera with higher spatial resolution (1280x1024 at 181Hz frame rate) was integrated into the PTT laboratory setup. Software tools were developed to ensure compatibility of new camera files with legacy effusivity reconstruction codes. The new camera was used to obtain 3-D reconstructions of AM IN718 nozzle plate and a particle filter plate. It was shown that PTT can scan through 2/3in-thick Inconel 718 plates in approximately 15s. Several modes of 3-D data visualization were explored, including using ImageJ and MATLAB software packages. The results demonstrate the capability of PTT in 3-D imaging of complex geometry AM structures. Intermediate results demonstrated in this report will be developed further to investigate detection of flaws in AM specimens.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2013

Annual Report: Carbon Capture Simulation Initiative (CCSI) (30 September 2013)

The Carbon Capture Simulation Initiative (CCSI) is a partnership among national laboratories, industry and academic institutions that is developing and deploying state-of-the-art computational modeling and simulation tools to accelerate the commercialization of carbon capture technologies from discovery to development, demonstration, and ultimately the widespread deployment to hundreds of power plants. The CCSI Toolset will provide end users in industry with a comprehensive, integrated suite of scientifically validated models, with uncertainty quantification (UQ), optimization, risk analysis and decision making capabilities. The CCSI Toolset incorporates commercial and open-source software currently in use by industry and is also developing new software tools as necessary to fill technology gaps identified during execution of the project. Ultimately, the CCSI Toolset will (1) enable promising concepts to be more quickly identified through rapid computational screening of devices and processes; (2) reduce the time to design and troubleshoot new devices and processes; (3) quantify the technical risk in taking technology from laboratory-scale to commercial-scale; and (4) stabilize deployment costs more quickly by replacing some of the physical operational tests with virtual power plant simulations. CCSI is led by the National Energy Technology Laboratory (NETL) and leverages the Department of Energy (DOE) national laboratories’ core strengths in modeling and simulation, bringing together the best capabilities at NETL, Los Alamos National Laboratory (LANL), Lawrence Berkeley National Laboratory (LBNL), Lawrence Livermore National Laboratory (LLNL), and Pacific Northwest National Laboratory (PNNL). The CCSI’s industrial partners provide representation from the power generation industry, equipment manufacturers, technology providers and engineering and construction firms. The CCSI’s academic participants (Carnegie Mellon University, Princeton University, West Virginia University, Boston University and the University of Texas at Austin) bring unparalleled expertise in multiphase flow reactors, combustion, process synthesis and optimization, planning and scheduling, and process control techniques for energy processes. During Fiscal Year (FY) 13, CCSI announced the initial release of its first set of computational tools and models during the October 2012 meeting of its Industry Advisory Board. This initial release led to five companies licensing the CCSI Toolset under a Test and Evaluation Agreement this year. By the end of FY13, the CCSI Technical Team had completed development of an updated suite of computational tools and models. The list below summarizes the new and enhanced toolset components that were released following comprehensive testing during October 2013. 1. FOQUS. Framework for Optimization and Quantification of Uncertainty and Sensitivity. Package includes: FOQUS Graphic User Interface (GUI), simulation-based optimization engine, Turbine Client, and heat integration capabilities. There is also an updated simulation interface and new configuration GUI for connecting Aspen Plus or Aspen Custom Modeler (ACM) simulations to FOQUS and the Turbine Science Gateway. 2. A new MFIX-based Computational Fluid Dynamics (CFD) model to predict particle attrition. 3. A new dynamic reduced model (RM) builder, which generates computationally efficient RMs of the behavior of a dynamic system. 4. A completely re-written version of the algebraic surrogate model builder for optimization (ALAMO). The new version is several orders of magnitude faster than the initial release and eliminates the MATLAB dependency. 5. A new suite of high resolution filtered models for the hydrodynamics associated with horizontal cylindrical objects in a flow path. 6. The new Turbine Science Gateway (Cluster), which supports FOQUS for running multiple simulations for optimization or UQ using a local computer or cluster. 7. A new statistical tool (BSS-ANOVA-UQ) for calibration and validation of CFD models. 8. A new basic data submodel in Aspen Plus format for a representative high viscosity capture solvent, 2-MPZ system. 9. An updated RM tool for CFD (REVEAL) that can create a RM from MFIX. A new lightweight, stand-alone version will be available in late 2013. 10. An updated RM integration tool to convert the RM from REVEAL into a CAPE-OPEN or ACM model for use in a process simulator. 11. An updated suite of unified steady-state and dynamic process models for solid sorbent carbon capture included bubbling fluidized bed and moving bed reactors. 12. An updated and unified set of compressor models including steady-state design point model and dynamic model with surge detection. 13. A new framework for the synthesis and optimization of coal oxycombustion power plants using advanced optimization algorithms. This release focuses on modeling and optimization of a cryogenic air separation unit (ASU). 14. A new technical risk model in spreadsheet format. 15. An updated version of the sorbent kinetic/equilibrium model for parameter estimation for the 1st generation sorbent model. 16. An updated process synthesis superstructure model to determine optimal process configurations utilizing surrogate models from ALAMO for adsorption and regeneration in a solid sorbent process. 17. Validation models for NETL Carbon Capture Unit utilizing sorbent AX. Additional validation models will be available for sorbent 32D in 2014. 18. An updated hollow fiber membrane model and system example for carbon capture. 19. An updated reference power plant model in Thermoflex that includes additional steam extraction and reinjection points to enable heat integration module. 20. An updated financial risk model in spreadsheet format.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2014

Coastal Ohio Wind Project for Reduced Barriers to Deployment of Offshore Wind Energy

The Coastal Ohio Wind Project was created to establish the viability of wind turbines on the coastal and offshore regions of Northern Ohio. The project’s main goal was to improve operational unit strategies used for environmental impact assessment of offshore turbines on lake wildlife by optimizing and fusing data from the multi-instrument surveillance system and providing an engineering analysis of potential design/operational alternatives for offshore wind turbines. The project also developed a general economic model for offshore WTG deployment to quantify potential revenue losses due to wind turbine shutdown related to ice and avian issues. In a previous phase of this project (Award Number: DE-FG36-06GO86096), we developed a surveillance system that was used to collect different parameters such as passage rates, flight paths, flight directions, and flight altitudes of nocturnal migrating species, movements of birds and bats, and bird calls for assessing patterns and peak passage rates during migration. To derive such parameters we used thermal IR imaging cameras, acoustic recorders, and marine radar Furuno (XANK250), which was coupled with a XIR3000B digitizing card from Russell Technologies and open source radR processing software. The integration yielded a development of different computational techniques and methods, which we further developed and optimized as a combined surveillance system. To accomplish this task we implemented marine radar calibration, optimization of processing parameters, and fusion of the multi-sensor data in order to make inferences about the potential avian targets. The main goal of the data fusion from the multi-sensor environment was aimed at reduction of uncertainties while providing acceptable confidence levels with detailed information about the migration patterns. Another component comprised of an assessment of wind resources in a near lake environment and an investigation of the effectiveness of ice coating materials to mitigate adverse effects of ice formation on wind turbine structures. Firstly, a Zephir LiDAR system was acquired and installed at Woodlands School in Huron, Ohio, which is located near Lake Erie. Wind resource data were obtained at ten measurement heights, 200m, 150m, 100m, 80m, 60m, 40m, 38m, 30m, 20m, and 10m. The Woodlands School’s wind turbine anemometer also measured the wind speed at the hub height. These data were collected for approximately one year. The hub anemometer data correlated well with the LiDAR wind speed measurements at the same height. The data also showed that on several days different power levels were recorded by the turbine at the same wind speed as indicated by the hub anemometer. The corresponding LiDAR data showed that this difference can be attributed to variability in the wind over the turbine rotor swept area, which the hub anemometer could not detect. The observation suggests that single point hub wind velocity measurements are inadequate to accurately estimate the power generated by a turbine at all times since the hub wind speed is not a good indicator of the wind speed over the turbine rotor swept area when winds are changing rapidly. To assess the effectiveness of ice coatings to mitigate the impact of ice on turbine structures, a closed-loop icing research tunnel (IRT) was designed and constructed. By controlling the temperature, air speed, water content and liquid droplet size, the tunnel enabled consistent and repeatable ice accretion under a variety of conditions with temperatures between approximately 0°C and -20°C and wind speeds up to 40 miles per hour in the tunnel’s test section. The tunnel’s cooling unit maintained the tunnel temperature within ±0.2°C. The coatings evaluated in the study were Boyd Coatings Research Company’s CRC6040R3, MicroPhase Coatings Inc.’s PhaseBreak TP, ESL and Flex coatings. Similar overall performance was observed in all coatings tested in that water droplets form on the test articles beginning at the stagnation region and spreading in the downstream direction in time. When comparing ice accumulation characteristics for the four coatings tested, for ice thickness during accumulation the CRC6040R3 had the least, followed by the ESL, Flex, and TP. However, when comparing the coatings’ ability to reduce ice adhesion, the Flex showed the highest adhesion reduction, followed by the ESL, TP and CRC 6040R3 coatings. The ice accumulated on the Flex coated surface shed under gravity when rotated 90 degrees following the tests while the other coatings required application of varying degrees of force to remove the ice. In conclusion, the ice coatings tested were not sufficient in preventing ice accumulation on all surfaces. However, Flex coating shows promise in mitigating ice on the rotor blades under the gravitational and centrifugal forces. Only the effect of gravity in shedding the ice was considered in this study. Further research will be needed to evaluate this coating on rotating blades in the icing tunnel to characterize its effectiveness. Lastly, the development of economic feasibility models used existing approaches adapted for offshore deployment in marine settings to one more suitable for Lake Erie deployment. Two different wind turbine models were tested and dynamic return on investment (ROI) model scenarios were generated. For the purpose of estimating power generation three bladed wind turbines of 3 MW capacity were selected including Model1- Leitwind LTW101-3.000-kW and Model2-Vostro V90-3.0 MW. The analysis were based on the revenue aspect of decision making of deploying wind turbines in the Ohio coastal region. The installation cost, maintenance and operational aspects were disregarded due to unavailability of data. The adjusted varying price (residential and industrial sector) and projected future price of electricity in different years suggested that the Leitwind model could generate $\$ $32.4 million of revenue in 25 years if the supply electricity is in the residential sector, while it would be $\$ $14.7million if the supply is in the industrial sector. For the Vostro model these figures are $\$ $28.6 million for residential sector and $\$ $12.9 million for industrial sector for 25 years.

17 WIND ENERGY↗