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DOE OSTI2023

Experimental and Numerical Investigation of Flow Boiling in Additive Manufactured Foam Structures With Vapor Pathways

Abstract The unique properties of metal foams make them potential candidates for a range of applications, including microsystem thermal management. Using additive manufacturing to create foam-type structures can improve upon prior thermal solutions by eliminating thermal interface materials and allowing for customization/local control of parameters. In the present investigation, flow boiling in additive-manufactured metal foams is investigated both experimentally and numerically. Two test samples, one with uniform structure and the other with pathways for vapor removal, are compared both experimentally and numerically. A conjugate computational fluid dynamics and heat transfer (CFD-HT) model utilizing a three-dimensional volume of fluid (VOF) model with accompanying evaporation/condensation model provided in-depth visualization of the boiling flow phenomena. The experiments generated the thermohydraulic performance over a range of heat fluxes, demonstrating that the sample incorporating dedicated vapor pathways performed better in both pressure and heat transfer performance metrics compared to the uniform foam. Additionally, negative system-level effects (i.e., hydraulic oscillations) were shown to be abated using the vapor removal structures. The numerical model yielded further insight into the factors contributing to the improved performance. Results indicated the pathways functioned as vapor removal channels, allowing the generated vapor to vent from the foam structure into the lanes. Further computational investigations demonstrated changes in flow regimes, where the addition of vapor channels caused the flow to change from churn to annular. Bubble behavior unique to the vapor pathway structure was studied, showing stagnant regions that eject vapor into the channel.

Engineering↗

DOE OSTI2024

Steam Condensation Scaled Experiment in the Presence of Non-condensable Gas for Reactor Containment Passive Safety Analysis

This study presents scaled experiments using steam condensation with non-condensable gas (NCG)—helium, simulating hydrogen—as these experiments are pivotal for water-cooled reactor passive containment cooling system (PCCS) design and analysis. Research into PCCSs for small modular reactors (SMRs) is especially important in light of SMR system design; however, studies in the literature reflect limitations due to test geometry and operational condition variations, without considering SMR prototypic design. To address these challenges, a scaled test facility was developed to accurately replicate SMR PCCSs. This facility includes vertical down-flow condensing test sections with 1-, 2-, and 4-in.-diameter condensing tubes, accompanied by annular water cooling. Experiments were conducted using both superheated and saturated steam, with steam mass flow rates varying from 55 to 66 kg/hr., in the presence of helium as the NCG mass flow rate ranges from 1.8 to 22 kg/hr. Test data were collected on (a) the axial temperatures of the annular cooling water; (b) the outer wall temperature of the condensers; and (c) the mass flow rate, temperature, and pressure at the test section inlets and outlets. These primary test data were used in conjunction with a standard data reduction methodology to estimate essential thermal parameters such as heat fluxes, heat transfer coefficients, and condensation rates. The effects of NCGs on steam condensation within the geometry of the scaled test sections were then presented in regard to various testing conditions.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2024

Presentation: Steam Condensation Scaled Experiment in the Presence of Non-condensable Gas for Reactor Containment Passive Safety Analysis

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2020

Revolutionizing Turbine Cooling with Micro-Architectures Enabled by Direct Metal Laser Sintering

The objective of this research effort was to explore innovative cooling architectures enabled by additive manufacturing techniques for improved turbine cooling performance. The ability to create complex internal geometries was leveraged to better distribute coolant as well as to integrate inherently unstable flow devices to enhance internal and external heat transfer. This was accomplished with a multi-faceted approach including analytical, experimental, and computational components. This final report documents progress during the total 4.25 year effort that was extended (at no additional cost) from the original 3-year cooperative agreement. Prior to starting the project, significant effort was invested in investigating innovative cooling designs from the open literature. When the project started, we quickly down-selected to 4 configurations: impingement jet fluidic oscillators (for internal leading edge cooling), reverse film cooling (for pressure surface), sweeping film cooling jets (for suction surface), and trailing edge slot cooling with microchannels. During the 2nd year, the reverse film cooling design was shown to be sub-optimal and work on that topic was halted. The three remaining technologies were integrated into a large scale nozzle guide vane and installed into a low-speed linear cascade facility for further interrogation. Initial results showed the sweeping film cooling jets (on the suction surface) to be the most promising technology compared to a baseline diffusion shaped film hole (777 design). The benefit was particularly evident at high blowing ratios (>1.5) when the 777 coolant film separated from the downstream surface. Benefits were also evident at elevated freestream turbulence levels. The leading edge cooling with unsteady jets was less effective in terms of peak or average cooling – however it was superior to round hole impingement cooling in terms of spatial uniformity. Finally, the trailing edge cooling design with micro-channels was scrapped in favor of a pinned arrangement with centerbody. During the 3rd year, the same three technologies were integrated into a transonic linear cascade for an assessment of compressibility effects. Again, the sweeping film cooling jets proved superior at high blowing ratios while the unsteady leading edge impingement and trailing edge pin-fins with centerbody designs yielded mixed results. Finally, during the 4th and final year, these 3 technologies were integrated into a direct metal laser sintered (DMLS) nozzle guide vane for testing in a high temperature, transonic annular vane cascade. The facility matches the flow temperature, Mach number, and coolant pressure ratios of an actual gas turbine. Before doing this, an additional series of tests were completed to validate a redesigned trailing edge cooling architecture. This final design included a centerbody with triangular pins between the centerbody and the vane external skin. The majority of these triangular pins are fabricated with a 30% gap to the centerbody – reducing their pressure drop considerably while still providing excellent heat transfer augmentation. This additional test campaign required an additional 3-month extension request to complete testing in the high temperature NGV test facility (Turbine Reacting Flow Rig – TuRFR). Testing of the DMLS vane in TuRFR pitted the 3 innovative cooling technologies against more traditional technologies (shaped 777 film hole, round impingement jet, and full pin arrangement in the trailing edge. The sweeping film cooling jets (on the suction surface) showed approximately 15% improvement in overall effectiveness compared to the 777 film hole while the trailing edge showed up to 20% improvement. The leading edge impingement was disappointing with a substantially lower effectiveness than traditional direct impingement. In summary, the study was successful in demonstrating that DMLS-enabled cooling technologies can yield significant gains in cooling performance.

03 NATURAL GAS↗

DOE OSTI2022

Design of an Additively Manufactured Recuperator With 800 °C Inlet Temperature for sCO2 Power Cycle Application

Abstract Recuperators with design temperatures at and above 800 °C can further increase the thermal efficiency of supercritical CO2 power cycles by enabling higher turbine exhaust temperatures. Mar-M247 is a well-suited nickel-based superalloy for high temperature service due to its high creep strength that prevents excessive material thickness being required for pressure containment. Additive manufacturing using a high-speed laser-directed energy deposition (L-DED) process presents a promising solution, with build trials demonstrating the ability to produce nonconventional flow channels for enhanced heat transfer. A design process is presented that includes aerothermal and mechanical evaluation to maximize performance within the constraints of the manufacturing process. A 2-D heat transfer network and pressure drop code allows prediction of flow distribution and its effect on overall thermal performance. Established literature correlations, along with CFD simulation, inform the prediction of heat transfer coefficients and friction factors for the flowpaths and enhancement features in the heat exchanger core. Mechanical evaluation using finite element analysis (FEA) modeling with the intent of the ASME Boiler & Pressure Vessel Code (BPVC) Section VIII, Div. 2 assesses the operational safety of the design. The detailed design features annular finned passages that take advantage of helical flow paths to distribute the flow from separated headers to shared heat transfer surfaces. Performance predictions for the recuperator at a 50 kW scale provide insights into the feasibility of the additively manufactured (AM) process to produce recuperators on a commercial scale that extend existing operating envelopes.

Engineering↗

DOE OSTI2023

Heat exchangers and related systems and methods

A heat exchanger may include a main body with an inlet plenum and an outlet plenum at a first end, and a header at a second end. At least one elongated shaft may extend from the outlet plenum to the header. At least one heat pipe may be coupled to the header and a portion of each heat pipe may be positioned within a corresponding elongated shaft defining an annular space between each heat pipe and each corresponding elongated shaft. A flow skirt may include a manifold located between the inlet plenum and the outlet plenum of the main body. At least one elongated tube may extend from the manifold. Each elongated tube may be positioned within a corresponding annular space between each heat pipe and each corresponding elongated shaft, dividing the annular space into two concentric annular channels comprising an inner annular channel and an outer annular channel.

Yoon, SuJong↗

DOE OSTI2023

The Intrinsic 150‐Day Periodicity of the Southern Hemisphere Extratropical Large‐Scale Atmospheric Circulation

Abstract The variability of the Southern Hemisphere (SH) extratropical large‐scale circulation is dominated by the Southern Annular Mode (SAM), whose timescale is extensively used as a key metric in evaluating state‐of‐the‐art climate models. Past observational and theoretical studies suggest that the SAM lacks any internally generated (intrinsic) periodicity. Here, we show, using observations and a climate model hierarchy, that the SAM has an intrinsic 150‐day periodicity. This periodicity is robustly detectable in the power spectra and principal oscillation patterns (aka dynamical mode decomposition) of the zonal‐mean circulation, and in hemispheric‐scale precipitation and ocean surface wind stress. The 150‐day period is consistent with the predictions of a new reduced‐order model for the SAM, which suggests that this periodicity is associated with a complex interaction of turbulent eddies and zonal wind anomalies, as the latter propagate from low to high latitudes. These findings present a rare example of periodic oscillations arising from the internal dynamics of the extratropical turbulent circulations. Based on these findings, we further propose a new metric for evaluating climate models, and show that some of the previously reported shortcomings and improvements in simulating SAM's variability connect to the models' ability in reproducing this periodicity. We argue that this periodicity should be considered in evaluating climate models and understanding the past, current, and projected Southern Hemisphere climate variability.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2024

Utah FORGE 1-2410: Development of a Smart Completion and Stimulation Solution - 2024 Annual Workshop Presentation

This is a presentation on the Development of a Smart Completion & Stimulation Solution by Welltec, presented by Ricardo Vasques. This video slide presentation discusses the development of an (1) annular isolation system, (2) a stimulation isolation system, and (3) a multi open-close flow system for geothermal environments. This presentation was featured in the Utah FORGE R&D Annual Workshop on August 15, 2024.

15 GEOTHERMAL ENERGY↗

DOE OSTI2026

Computational Thermal Hydraulics of a High-Performance Low-Enriched-Uranium Annular Target for HFIR Irradiation

Molybdenum-99 has historically been generated via isolation from fissioned highly enriched uranium (HEU) targets. Here, this isotope is in high demand due to its daily use across the world in radiopharmaceutical medical procedures. The primary objective of this work was to design and analyze an experimental target assembly containing one low-enriched-uranium (LEU) annular target for irradiation at the High Flux Isotope Reactor (HFIR). Efforts included incorporating spatially dependent energy sources from neutron and gamma interactions, quantifying thermal contact conductance at material interfaces, performing grid-independent studies, comparing turbulence models, and simulating various steady-state and transient scenarios relevant for irradiation qualification and eventual insertion. These models provide velocity, pressure, and temperature distributions in both space and time. Such results enable the selection of an appropriate irradiation location, fission rate density, and flow-limiting orifice size and demonstrate compliance with HFIR safety requirements such that insertion into the reactor can be approved. This analysis shows that across all scenarios, wetted surface temperatures remain below the coolant saturation temperature with no net vapor formation in the coolant. In every scenario, all components stay below 30% of the aluminum 6061 melting temperature. Computational fluid dynamics and system-level models predict peak target temperatures that agree within 4%, though the predicted axial location of the peak differs by about 10% of the heated length due to differences in flow development length. These results de-risk the irradiation of LEU (annular targets) and strengthen a domestic, HEU-independent 99 Mo supply by providing important fuel performance data to form the foundation for a robust licensing basis.

Molybdenum-99↗

DOE OSTI2023

Utah FORGE 1-2410: Development of a Smart Completion and Stimulation Solution - Workshop Presentation

This is a presentation on the Development of a Smart Completion & Stimulation Solution project by Welltec in collaboration with the University of Oklahoma, presented by Yosafat Esquitin, a Senior Business Development Manager at Welltec. The project's objective was to develop an annular isolation system, a stimulation isolation system, and a multi-open-close flow system for geothermal environments. These systems were developed to enable effective zonal isolation and stimulation, implement downhole Enhanced Geothermal Systems (EGS) in any location, and extend the productive life of the geothermal well. This presentation was featured in the Utah FORGE R&D Annual Workshop on September 7, 2023. The workshop provided a valuable opportunity to explore the progress made in each of the 17 Research and Development projects funded under Solicitation 2020-1 which aim to enhance our understanding of the crucial factors influencing the development EGS reservoirs and resources.

15 GEOTHERMAL ENERGY↗

DOE OSTI2022

A whole-core steady-state thermal-hydraulic model for annular fuel type fluoride-salt-cooled reactors

A whole-core, steady-state thermal-hydraulic model is developed for the fluoride-salt-cooled small modular advanced high-temperature reactor (SmAHTR) that employs an annular fuel configuration. This pre-conceptual reactor design by Oak Ridge National Laboratory (ORNL) has the annular fuel and moderator pins arranged in a hexagonal layout. The FLiBe coolant flows from the bottom to the top of the core, parallel to the hexagonal bundle. The fuel and moderator pins in the core are discretized into finite volumes and the 3-D heat conduction equation is solved to obtain the temperature profile. Inter-fuel assembly conduction is also addressed. For this fuel assembly configuration, the coolant flows through two distinct regions – the hexagonal pin bundle and the annulus between the fuel pin and the tie rod. The fluid flow through the hexagonal bundles is modeled using the subchannel approach, in which the coolant region is discretized into corner, edge and interior subchannels and the resulting conservation equations are systematically solved. The 1-D mass, momentum and energy equations are solved for the annulus channels between the fuel pin and the tie rod. Pertinent closure models from the literature are employed to close the system of equations. We also performed a preliminary code-to-code comparison between the present model and a CFD model.. The resulting thermal-hydraulic model can provide temperature, flow rate and pressure drop profiles for the different solid and fluid regions throughout the entire core. Whole-core thermal-hydraulic results for a representative power profile are presented and discussed.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

Effect of outer-cylinder rotation on the radially heated Taylor–Couette flow

A Taylor–Couette setup with radial heating is considered where a Boussinesq fluid is sheared in the annular region between two concentric, independently rotating cylinders maintained at different temperatures. Linear stability analysis is performed to determine the Taylor number for the onset of instability. Two radius ratios corresponding to wide and thin gaps with several rotation rate ratios are considered. The rotation of the outer cylinder is found to have a general stabilizing effect on the stability threshold as compared to pure inner-cylinder rotation, with a few exceptions. The radial heating sets up an axial flow which breaks the reflection symmetry of isothermal Taylor–Couette flow in the axial coordinate. This symmetry breaking separates linear stability thresholds, and we find the fastest growing modes with both positive and negative azimuthal numbers for different parameters. Another important finding of the current study is the discovery of unstable modes in the Rayleigh-stable regime. Furthermore, closed disconnected neutral curves (CDNCs) are observed for both wide and thin gaps which can separate from or merge into open neutral–stability curves. Alternatively, CDNCs can also morph into open neutral stability curves as the rotation rate ratio is changed. CDNCs are observed to be sensitive to changes in control parameters, and their appearance/disappearance is shown to induce discontinuous jumps in the critical Taylor number. Finally, for both wide and thin gaps, the fastest-growing modes found in the pure corotation case are shown to have their origins in the instability islands at smaller values of rotation rate ratios.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2022

Experimental and Numerical Study on the Effect of Annular Combustor Design on Thermal Uniformity Jet in Crossflow

Abstract Non-uniformity of the exit flow temperature represents one of the significant damages to gas-turbine components, particularly turbine blades. This may occur in the course of gas-turbine operation. This paper aims to provide passive techniques by modifying the combustor design rather than changing the flow parameters to improve the thermal uniformity and turbine blades to reduce thermal stresses and increase turbine blades’ life span. An acceptable agreement between the numerical and experimental results has been achieved, and the agreement includes the velocity and temperature profile. Four different angles have been tested numerically and experimentally with a maximum error of 5% at two different Reynolds numbers. Designing the outer combustor surface with a 45-deg angle bend can give a more uniform temperature distribution of 37% higher than the basic design with only a 0.5% higher pressure drop.

Energy & Fuels↗

DOE OSTI2022

On the effects of reactant stratification and wall curvature in non-premixed rotating detonation combustors

The optimization of non-premixed rotating detonation combustors (RDCs) requires improved understanding of the coupled effects of reactant stratification, fluid property gradients, and complex shock-wave interactions on the detonation wave structure within annular geometries. In the current work, simultaneous orthogonal views of chemiluminescence and hydroxyl planar laser-induced fluorescence (PLIF) are utilized to establish the existence of a dual-wave system characterized by leading and trailing detonation waves that are closely coupled by the local flow physics. These features are persistent over a wide range of mass flow rates and are consistent with prior observations of non-premixed rotating detonations in annular geometries. The detailed instantaneous time sequences are compared with a 3D reactive unsteady Reynolds averaged Navier-Stokes (URANS) simulation to more clearly elucidate the in-situ combustion dynamics and the sensitivity to reactant inlet conditions. It is found that the dual-wave system results from unburned reactants that survive the leading detonation wave in the injector near field and are consumed within a trailing azimuthal reflected-shock combustion (ARSC) zone. By contrast, the injector far field is characterized by rapid mixing due to a sudden drop to subsonic conditions, and the bifurcated detonation wave structure collapses into a stronger, single-wave detonation front with higher overall pressure ratio as compared with the dual-wave system. While each RDC will have different inflow, mixing, and combustion characteristics, the underlying interactions between the stratified reactants and azimuthal wave dynamics identified through the combination of advanced MHz-rate diagnostics and 3D numerical simulations have important implications for the study of detonation wave stability, mode transition, and combustion efficiency in non-premixed annular RDCs.

3D URANS↗

DOE OSTI2024

High Performance Heat Pipe Power Transient Testing at SPHERE Facility

Microreactors are being researched, designed, and built at Idaho National Laboratory (INL). Microreactors are small reactors defined at less than 20MW of power. These reactor concepts are also being looked at throughout industry for various applications. An important aspect of these reactor designs is economic feasibility i.e. lower overnight capital cost. The driving factors for implementing microreactors are quick setup and takedown, minimal operators, and the ability to manufacture them readily and to fit in mid-sized containers for transport. A specific area of research to aid in successful integration of these factors within the designs is passive heat removal of the core’s thermal power. Interest in heat pipes to achieve this passive heat removal has been shown across multiple industry partners. Because of this interest, INL has developed a test facility to facilitate experimental tests for sodium filled heat pipes. INL has developed the Single Primary Heat Extraction and Removal Emulator (SPHERE) facility to run experiments on high performance, sodium filled heat pipes. As mentioned above, heat pipes are passive heat transfer devices. Radially, heat pipes are broken up into an outer wall, a small annular gap, a wick structure, and a centerline gap. They function by utilizing latent heat transfer. Heat pipes are traditionally separated into three regions, an evaporator (heat input), an adiabatic region, and finally a condenser region (heat removal). As heat is being applied to the evaporator, the working fluid undergoes a phase change to a vapor. This phase change causes a differential pressure across the axial length of the pipe driving flow down the center gap of the heat pipe. The vapor flows down past the adiabatic region to the condenser where the heat is removed. This heat removal forces the working fluid to phase change back to a liquid. The wick structure is then utilized to drive the flow back towards the evaporator by capillary forces. This backflow is aided by the annular gap. Because this heat transfer mechanism functions with latent heat transfer, the heat pipe is close to isothermal down the axial length. Heat pipes can operate under a wide range of working fluids. Considerations for these working fluids are primarily driven by operating temperatures amongst other important factors based around overall performance. Sodium filled heat pipes operate from 450°C up to 900°C. This temperature range works well for the current microreactor designs. In conjunction with this experimental capability, INL has developed a modeling software to simulate heat pipe physics within reactor cores. This modeling software is called Sockeye and functions under the established INL Multiphysics Object Oriented Simulation Environment (MOOSE). SPHERE also supports Sockeye development by providing the modeling team with experimental data on an array of setups and operating parameters to support validation efforts. A power transient experiment was performed utilizing the SPHERE facility to continue to aid with Sockeye development. The testing followed a proposed test plan to ramp up and down the temperature of the heat pipe. Sockeye models steady state heat pipe operation with high accuracy, the data provided by the power transient testing aims to assist with the validation efforts and further enhance transient modeling capability of the tool [2].

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

Film condensation with high heat fluxes and scaled experiments using pure steam for reactor containment cooling

Condensation tests were performed using a newly developed test facility for scaling the passive containment cooling system (PCCS) to a small modular reactor (SMR). The PCCS of the SMR plays a pivotal role in ensuring greater safety, reliability, and compactness than what is afforded by traditional reactors. Therefore, a well-designed PCCS is essential to SMRs. However, previous studies and test data were unsuitable for scaling, due to high variation in the test geometry and operating conditions. This study intends to close this research gap by using a novel designed scaled test facility consisting of vertical condensing test sections featuring 1-, 2-, and 4-inch-diameter condensing tubes with annular water cooling, and by applying superheated and saturated steam with different steam mass flow ranges of 5–25 g/s. Further, the primary test data, including axial temperatures, mass flow rates, and pressures, were used in conjunction with a standard data reduction method to estimate critical parameters such as heat fluxes, heat transfer coefficients, and condensation rates. These scaled test data would support improving empirical correlations and validating condensation models to identify scaling distortion for SMR PCCSs.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2020

Unraveling the individual influences of supports and ionic liquid coatings on the catalytic properties of supported iridium complexes and iridium clusters

In this work, supported iridium complexes were synthesized by the reaction of Ir(CO) 2 (acac) (acac = acetylacetonato) with SiO 2 , γ-Al 2 O 3 , and MgO. Extended X-ray absorption fine structure (EXAFS) and infrared (IR) spectra demonstrate that the iridium was present as atomically dispersed species anchored to each support. The samples were treated in flowing H 2 at 673 K to form supported iridium clusters. EXAFS spectra and high-angle annular dark-field scanning transmission electron microscopy images demonstrate that the average diameter of the iridium clusters on each support was approximately 1.2 nm. Furthermore, the catalysts before and after cluster formation were coated with each of a family of 1,3-dialkylimidazolium ionic liquids (ILs) having varying electron-donor tendencies probed by their υ(C2H) frequencies determined by IR spectroscopy. The coated and uncoated samples were tested as catalysts for partial hydrogenation of 1,3-butadiene in a flow reactor at 333 K, with turnover frequencies determined from differential conversions. The individual influences of the IL coatings and supports on the catalyst performance were found to depend strongly on whether the iridium was site-isolated complexes or present in clusters. The IL coatings as ligands exerted dominant effects on the clusters as catalysts, whereas the supports exerted dominant effects on the isolated iridium atoms. The results indicate how to tune the effects of metal nuclearity, IL coatings, and supports on the electronic environments and catalytic properties of the metals.

1,3-Butadiene hydrogenation↗

DOE OSTI2025

Theoretical description of atomtronic Josephson junctions in an optical lattice

Experimental realizations of “atomtronic” Josephson junctions have recently been created in annular traps in relative rotation with respect to potential barriers that generate the weak links. If these devices are additionally subjected to an optical lattice potential, then they can incorporate strong-coupling Mott physics within the design, which can modify the behavior and can allow for interesting new configurations of barriers and of superfluid flow patterns. We examine theoretically the behavior of a Bose superfluid in an optical lattice in the presence of an annular trap and a barrier across the annular region which acts as a Josephson junction. As the superfluid is rotated, circulating super-currents appear. Beyond a threshold superfluid velocity, phase slips develop, which generate vortices. We use a finite temperature strong-coupling expansion about the mean-field solution of the Bose Hubbard model to calculate various properties of such devices. Additionally, we discuss some of the rich behavior that can result when there are Mott regions within the system.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗