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DOE OSTI2021

Report on Year-3 of Water NSTF Matrix Testing: Two-Phase Parametric Test Series

The Natural convection Shutdown heat removal Test Facility (NSTF) is large scale test facility constructed at Argonne National Laboratory to generate NQA-1 qualified validation data for passive decay heat removal systems in advanced reactor concepts. With support from the Department of Energy (DOE) offices of Advanced Reactor Technologies (ART) and Advanced Reactors Regulatory Development (RD), this facility reflects key features of a ½ scale, water-based, Reactor Cavity Cooling System (RCCS) and is intended to study the behavior, bound performance, and ultimately guide design decisions for passive decay heat removal systems. Since the facility also retains all aspects common to a fundamental boiling water thermosiphon, the generated experimental data sets are well poised to advance the understanding of fundamental natural circulation boiling and two-phase flow phenomena.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

FY22 Progress on Computational Modeling of the Water-Based NSTF

This report summarizes the system-level modeling effort by Argonne National Laboratory (Argonne) of the Natural convection Shutdown heat removal Test Facility (NSTF) in FY22. As an extension of the effort from FY21, this year’s work focuses primarily on the two-phase modeling of the NSTF using RELAP5-3D, particularly with the inclusion of the cavity model. The results from simulations were used to compare against experimental data for benchmarking purposes of the RELAP5 deck. Additionally, RELAP5 was used as a predictive tool to guide planned test operations and identify expected system behaviors. In the first part of this report, details are provided of the cavity omitted model where heat flux is applied directly as a boundary condition to the risers. The general trend predicted by the RELAP5 model matches that from the experimental data when a single-phase natural circulation flow is first established, followed by an oscillatory two-phase period and finally a stable two-phase flow. However, the onset of oscillations is predicted early by the model due to the smaller thermal mixing region in the tank. However, by expanding the simulated thermal mixing region in the tank, the onset of oscillations predicted by the model is able to match that from the experiment. These oscillations where studied in depth and are deduced to be flashing-induced instability. The model was then modified to simulate an accident scenario case where a representative heat load based on the full-scale Framatome’s 625 MW t SC-HTGR was applied directly to the riser channels. The simulated initial and boundary conditions were identical to those performed experimentally, facilitating direct comparisons between the predicted and experimental results. It was determined that the results showed some discrepancies remain, likely due to the overprediction of vapor generation rate by the computer model. In the second part of this report, the cavity model is re-introduced where it is observed that the RELAP5 prediction is now able to capture the major trends of the observed flow commonly observed during two-phase conditions. However, the onset of oscillations is once again predicted early by the model, possibly caused by the underprediction of heat loss from the heater and cavity. This is likely due to the omission of support structures in the cavity that can act as additional pathways for heat to escape to the environment. To overcome the underprediction of heat loss, part of the insulation surrounding the cavity side panels and the back of the heaters are removed to allow heat to escape directly to the environment, which then improves the RELAP5 prediction. Parametric studies are also performed to investigate the effects of heater power, tank inventory level, and tank gas space pressure on flow behaviors, also in direct comparison to conditions tested experimentally. User option-61 in the RELAP5-3D input deck, which changes the heat transfer coefficient correlations used for calculating the vapor generation, is also investigated where it is found that by enabling the option, the overall duration of oscillations is increased and matches that from the experiment better. The RELAP5 model is further benchmarked with a header inlet- throttling case where it is observed that the prediction from the model fails to capture some major features observed in the experiment. By using a modified loss coefficient curve for the valve, the accuracy of the prediction is improved where most of the major features observed in the experiment are predicted by the model. Lastly, the model is benchmarked with an inventory depletion scenario where it is observed that despite the modeling limitation of RELAP5, the prediction shows good agreement with the experimental data where major trends and features are captured by the model. Future work will see continued development of the current RELAP5-3D input deck of the NSTF to both improve the accuracy of the model’s predictive capability and continuing serving the experimental program. The mutually beneficial relationship between analysis and experimental efforts has become integral to the parent NSTF program, and the greater objective to fully understand and accurately predict the heat removal performance of a full scale RCCS concept.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2024

Modeling Flow and Particle Deposition in a Spent Nuclear Fuel Assembly

CFD (Computational Fluid Dynamic) simulation of aerosol-laden natural convective flow and particle deposition in a spent fuel storage canister with 37 assemblies is currently computationally prohibitive. PWR (Pressurized Water Reactor) assemblies have up to 289 pins or tubes with several spacer grids to align the pins. Spacer grids with mixing vanes induce swirling during operation to increase heat transfer. Each spacer grid contains hundreds of small structures such as retaining clips, channel walls, and openings. The largest canisters store 37 PWR assemblies thus, there are numerous pins, tubes, and spacer grids for which the flow region between and around these structures needs to be determined along with the movement and deposition of aerosol particles. Because of the complicated geometry, modeling the intricate flow even for just one assembly is currently impractical. Nonetheless, we are developing techniques for a practical model to assess the natural aerosol particle deposition process in a canister in the event that a release occurs from one or more fuel pins. In the previous work it was demonstrated that CFD can model the flow through a PWR spacer grid with mixing vanes, including particle deposition, in a reasonable amount of time on a personal computer. In this work, the analysis is extended to include the bypass region between an assembly and the canister basket walls. It is shown that the flow velocity in the bypass region is about three times that of the interstitial region between the pins. The lengths before and after the spacer grid are also extended to determine when the flow becomes fully developed. In addition, the approach of computationally “stitching together” segments of an assembly is demonstrated with the plan to ultimately model a full assembly. The fraction of particles that are deposited in a segment with a spacer grid is determined as a function of particle size and flow velocity.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Transient Modeling and Simulation of a Generic Stable Salt Reactor

A SAM system-level model of a generic stable salt reactor has been developed to investigate thermal-hydraulic behavior and safety performance under steady and transient conditions. The model integrates information generated from a reactor physics analysis using PROTEUS and PERSENT, and a computation fluid dynamics (CFD) analysis using STAR-CCM+. A loose, iterative coupling scheme between PROTEUS and SAM is implemented to calculate the equilibrium power and temperature distributions in the steady-state critical core condition. The converged steady-state model is then used in PERSENT to calculate the four reactivity feedback temperature coefficients (Doppler, fuel density, coolant density, and core radial expansion) and kinetic parameters that are needed in SAM to model the temperature feedback effects in transient simulations. Within the fully enclosed liquid fuel pins, natural convection is the dominant heat transfer mechanism. The STAR-CCM+ model of the fuel pin considers conjugate heat transfer from the liquid fuel salt to the pin cladding and external reactor coolant. The CFD results of the axial and radial temperature profiles are used to empirically determine an effective fuel salt thermal conductivity in the SAM fuel pin model so that the temperatures predicted by the SAM model match as closely as possible the CFD results. In the central region of the fuel pin, the effective thermal conductivity is as high as similar to 60 times the physical fuel salt thermal conductivity. The whole-plant SAM model is then used to simulate an unprotected station blackout transient. The results of this simulation showed that the large negative fuel axial expansion reactivity feedback reduces fission power to similar to 2.4% nominal power. The core is cooled by natural circulation, which removes heat in the core to the emergency heat removal system, and ultimately, to the ambient. However, peak fuel salt and cladding temperatures can potentially reach as high as 1500 K, albeit briefly, if the shutdown mechanism fails to operate.

stable salt reactor; transient simulations; system↗
DOE OSTI2024

Intracore Natural Circulation Study in the High Temperature Test Facility

The development of the Modular High-Temperature Gas-Cooled Reactor is a significant milestone in advanced nuclear reactor technology. One of the concerns for the reactor’s safe operation is the effects of a loss-of-flow accident (LOFA) where the coolant circulators are tripped, and forced coolant flow through the core is lost. Depending on the steam generator placement, loop or intracore natural circulation develops to help transfer heat from the core to the reactor cavity, cooling system. This paper investigates the fundamental physical phenomena associated with intracore coolant natural circulation flow in a one-sixth Computational Fluid Dynamics (CFD) model of the Oregon State University High Temperature Test Facility (OSU HTTF) following a loss-of-flow accident transient. This study employs conjugate heat transfer and steady-state flow along with an SST k-ω turbulence model to characterize the phenomenon of core channel-to-channel natural convection. Previous studies have revealed the importance of complex flow distribution in the inlet and outlet plenums with the potential to generate hot coolant jets. For this reason, complete upper and lower plenum volumes are included in the analyzed computational domain. CFD results also include parametric studies performed for a mesh sensitivity analysis, generated using the STAR-CCM+ software. The resulting channel axial velocities and flow directions support the test facility scaling analysis and similarity group distortions calculation.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Submersible Multistage Centrifugal Pump for Versatile Test Reactor Cartridge Test Loop

Submersible multistage centrifugal pumps are ideal for pumping in narrow confined spaces and achieving necessary head pressures and flow rates. Once a diameter is determined then manipulation of the number of stages and motor speed are all that are required to meet desired flow conditions. The Versatile Test Reactor (VTR) closed loop cartridge systems will need forced convection cooling independent of the main reactor. A multistage centrifugal pump can meet the necessary flow rates and pumping pressures while minimizing space taken. The pump considered for this work was based off a deep well submersible pump, a variation of a multistage centrifugal pump. We experimented with two pump sizes, 5 cm (2 inch) and 7.5 cm (3 inch) diameters. These diameters were chosen to fit into the inner diameter of standard 5 and 7.5 (2 and 3 inch) Schedule 40 pipe, respectively. This made the design for the test loop both simpler and less expensive as the need for an engineered pump housing was eliminated. Initial test cartridge planning indicated space for only a 5 cm (2 inch) diameter pump, though early testing of this size showed the need for an abnormally high-speed and high-power motor. Fine tuning of the cartridge design allowed a pump size increase to 7.5 cm (3 inches), which was the pump size most extensively tested in this work. The test loop is composed of various sizes of PVC and aluminum piping components in a loop configuration. The pump is driven by a Pittman 250 W (1/3 horsepower) electric motor with maximum speed of 3,450 RPM. Testing consisted of running the pump at a constant motor speed while varying a control valve to restrict flow through the loop, with differential pressure and flow rate recorded. This was done for one and two stage configurations for the 5 cm (2 inch) diameter impeller design and one, two, and three stage configurations for the 7.5 cm (3 inch diameter) impeller design, respectively. Due to pumping power requirements, two and three stage 7.5 cm (3 inch) diameter impeller testing at higher flowrates lowered the motor speed substantially. In regions where motor speed could not be maintained constant, the data were discarded. The test loop was also reconfigured to allow for the pump to be tested for pressure drop in a stalled or inoperable (0 RPM) flow condition. Demonstration of adequate natural convection cooling of the test cartridge fuel type is necessary under accident conditions, and this will depend upon the flow resistance through the impeller assembly when the pump is not operating. Thus, accurate knowledge of the effective impeller assembly loss coefficient is important for safety evaluations. The test loop was modified to provide water inlet and outlets on either side of the pump impeller stack, and a metered flow of lab water was provided in order to measure the pressure drop across the cartridges as a function of flowrate. Data from the pump head curve testing developed as part of this work and supported by analysis using pump head affinity laws indicates that a three stage 7.5 cm (3 inch) pump impeller design will meet target requirements for coolant flow within the VTR cartridge sodium cartridge at full power conditions [1] with margin; this corresponds to a flowrate of 45 l/min (12 gpm) at a pressure drop of 6.1 m (20 feet) of water head. The results of the pressure loss measurements across the impeller assembly when the pump is stationary (i.e., at 0 RPM) indicate that the pressure loss coefficient is 0.921 for a two impeller stack configuration; this value is calculated based on the flow velocity through the minimum available flow area within a single stage of the impeller which corresponds to 1.4 cm2.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Nature-inspired lotus-shaped fins combined with hybrid nanoparticles and metal foam for high-performance latent heat thermal energy storage

Latent heat thermal energy storage (LHTES) systems play a critical role in renewable energy integration by providing high energy density and nearly isothermal operation during phase transitions. However, their performance is often limited by slow melting/charging rates, which motivates the search for enhanced heat transfer designs. This study investigates the melting behavior of RT-82 phase change material (PCM) using novel lotus-shaped fins combined with copper metal foam and conductive graphene nanoparticles and carbon nanotubes. A two-dimensional enthalpy-porosity model in ANSYS Fluent was developed to simulate the charging/melting process, capturing non-thermal equilibrium between the foam and PCM/nano-PCM. In this study, effects of fin geometry, nanoparticle concentration, and foam porosity on melting dynamics and cost-performance trade-offs were investigated. Results showed that natural convection accelerated melting by ~12% compared to conduction-only scenarios. Optimized lotus-shaped fins with higher fin density (T3F4 and T3F10) achieved up to 63% faster melting relative to sparse configurations. Graphene nanoparticles improved thermal conductivity, with a 6% volume fraction, by reducing melting time by ~6.9%, while their combination with 75% porosity foam achieved a maximum reduction in the melting time of ~51% compared to pure PCM. Cost-performance analysis identified T3F4 as the most balanced design, offering rapid thermal response without excessive material costs, while moderate-density designs like T3S6 provided economical alternatives with acceptable performance. These results highlight the performance enhancement that can be achieved by integrating bio-inspired fins, nanoparticles, and foams, into compact and efficient LHTES for solar heating, building thermal management, and industrial waste-heat recovery applications.

25 ENERGY STORAGE↗
DOE OSTI2022

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

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

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

CFD modeling of natural circulation in LiCl-KCl molten salt closed loop

Characterizing flow within a molten salt closed-loop system is crucial for assessing system requirements, evaluating performance, and identifying potential flaws. Direct flow measurement using instrumentation is challenging due to extreme environmental conditions and the limitations associated with measuring molten salt flow under natural convection. Here, this study aims to provide comprehensive insights into the thermal-hydraulic behavior of a closed loop, with a particular focus on temperature distribution and velocity prediction. The Computational Fluid Dynamics (CFD) model demonstrated the capability to effectively simulate and predict both temperature distributions and flow velocities within the molten salt loop. The CFD model's predictive capability was validated by its ability to replicate temperature measurements under varying boundary conditions. The analysis revealed that the CFD model tends to underpredict temperatures in the cold leg and overpredict them in the hot leg, highlighting the need for continuous model refinement and acknowledging the limitations of using a steady-state approach. Furthermore, the potential of using external temperature measurements to estimate internal molten salt temperatures and predict flow velocity was explored, revealing that this approach could introduce up to a 5.5% error in flow velocity calculations. Line probes mapping temperature distributions across the tube's cross-section and molten salt provided valuable insights into temperature gradients, emphasizing the need for a thermal conductivity equation for molten salt with lower uncertainty to achieve more accurate temperature predictions of the system.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Performance evaluation of a wrapped around condenser for heat pump water heater applications

In this report, accurate performance evaluation of a wrapped-around condenser for heat pump water heaters (WHPWH) is critical since the COP of the system depends heavily on thermal stratification and condenser design. An analytical, quasi-steady state heat balance method has been developed to determine the optimal spacing between adjacent channels, tube diameter, tube shape, and total refrigerant charge amount for the condenser. The heat transfer rate is compared among three approaches: the refrigerant thermodynamic model, the condenser-wrap fin model, and the analytical natural convection model on the inside of the tank for the three regions based on the refrigerant phase (e.g., super-heated, saturated, or subcooled). The heat transfer rate was predicted by a combination of slug-plug and annular flow for a D-shaped helical tube. Experimental data were used as boundary conditions for validating the model. The rate of heat transfer based on tube shape and tank wall temperatures was compared by CFD analysis. Parametric analysis indicates a tradeoff between refrigerant mass, pressure drop, tube diameter, and tube length to maximize the heat transfer rate. The model suggests the saturated region length can be extended by 400%, and the condenser pressure drop can be reduced by 23% with an optimal spacing pattern.

42 ENGINEERING↗
DOE OSTI2025

Thermal Analysis of a Solid Particle Light-Trapping Planar Cavity Receiver Using Computational Fluid Dynamics

Concentrated solar power (CSP) is one of the most effective ways of harnessing solar power to create efficient, durable, and resilient energy systems. This study entails thermal modeling and analysis of a novel central tower receiver configuration. This receiver uses solid particles as the heat transfer fluid (HTF), a promising option for third-generation CSP systems. The configuration considered here is the light-trapping planar cavity receiver (LTPCR) introduced by the National Renewable Energy Laboratory. While heat transfer studies of various LTPCR subsystems have been done, system-level thermal analysis of the LTPCR receiver has not been attempted. This study also presents important sensitivity analyses of the operating parameters of the CSP system, which can help guide the design of future central tower receivers. This study employs Ansys Fluent as a computational fluid dynamics (CFD) tool to model fluid dynamics and heat transfer in the receiver, intending to quantify its thermal performance. The model seamlessly integrates Monte Carlo ray tracing data, which generates absorbed solar flux profiles from the heliostat field design, with the heat transfer characteristics of the fluidized particle bed. This unified model is designed to accurately predict the thermal behavior of the LTPCR. Analysis of preliminary results reveals that the primary loss mechanisms are radiative and natural convective losses, in that order. Based on observations from a baseline case, several strategies are suggested and numerically tested. These solutions include selective cooling of high-temperature regions and manipulation of particle bed parameters. Selective cooling of high-temperature regions reduced the peak temperature by 151 degrees C and decreased thermal losses by 0.9%. Improving the particle-wall heat transfer coefficient (P-W HTC) of the particle bed decreased the thermal losses by 1.7% and decreased the peak temperatures by 57 degrees C. Decreasing the particle inlet temperature (PIT) also reduced thermal losses by 3.5% and decreased peak temperatures by 29 degrees C. Compounding these strategies improved the thermal losses of the receiver from 13.5% in the baseline case to 7.5%. Additionally, the study explores the variation in thermal performance across different locations of the receiver, where a variation of thermal losses from 12.9% to 17.3% is found. This allows a comprehensive evaluation of potential improvements in efficiency and temperature management.

computational fluid dynamics↗
DOE OSTI2026

Demonstration of gold nanorod systems for enhanced total efficiency: Experimental and numerical analysis

This study investigates the photothermal performance of gold nanorods engineered to exhibit longitudinal plasmon resonances at 695 nm, 780 nm, and 970 nm. The work combines synthesis, structural characterization, extinction measurements, numerical modeling, and controlled temperature experiments to quantify how nanorod geometry, resonance tuning, concentration, and chamber shape jointly influence heat generation. Transmission electron microscopy confirms that increasing nanorod aspect ratio systematically shifts the longitudinal plasmon peak toward the near-infrared region. Extinction measurements show strong agreement with theoretical predictions, validating the numerical model across two independent datasets. Three chamber geometries were tested under laser excitation at 640 nm, 808 nm, and 980 nm: an ascending stepped base, a flat base, and a descending stepped base. Without nanorods, the ascending geometry produced the highest efficiency due to enhanced natural convection. After introducing gold nanorods, all geometries exhibited substantial thermal enhancement, with total efficiencies exceeding 20%. The strongest improvement was obtained for nanorods resonant at 780 nm with a mass concentration of 4.6 mg/mL implemented on the descending stepped-base geometry. This performance resulted from the combined effect of spectral overlapping with the 808 nm laser, the highest nanorod concentration, and localized heat accumulation that intensified buoyancy-driven flow. The findings demonstrate that total efficiency is governed by a synergistic interplay between optical resonance, nanoparticle concentration, and macroscopic chamber design, revealing the system-level coupling between nanoscale plasmonic absorption and macroscale heat-transfer phenomena. The results provide a validated framework for tuning nanoscale plasmonic absorbers and optimizing thermal systems for applications requiring efficient light-to-heat conversion.

77 NANOSCIENCE AND NANOTECHNOLOGY↗
DOE OSTI2023

Thermal conductivity measurement using modulated photothermal radiometry for nitrate and chloride molten salts

Molten salts are being used or explored for thermal energy storage and conversion systems in concentrating solar power and nuclear power plants. Thermal conductivity of molten salts is an important thermophysical property dictating the performance and cost of these systems, but its accurate measurement has been challenging, as evidenced by wide scattering of existing data in literature. The corrosive and conducting nature of these fluids also leads to time consuming sample preparation processes of many contact-based measurements. Here, in this work, we report the measurement of thermal conductivity of molten salts using a modulated photothermal radiometry (MPR) technique, which is a laser-based, non-contact, frequency-domain method adopted for molten salts for the first time. By unitizing the advantages of front side sensing of frequency-domain measurements and the vertical holder orientation, the technique can minimize the natural convection and salt creeping effects, thus yielding accurate molten salt thermal conductivity . The MPR technique is first calibrated using standard molten materials including paraffin wax and sulfur. It is then applied on measuring pure nitrate salts (NaNO 3 and KNO 3 ), solar salt (NaNO 3 –KNO 3 mixture), and chloride salt (NaCl–KCl–MgCl 2 ). The measurement results are compared with data from literature, especially those obtained from laser flash analysis (LFA). Our results demonstrate that the MPR is a convenient and reliable technique of measuring thermal conductivity of molten salts. Accurate thermal conductivity data of molten salts will be valuable in developing the next-generation high-temperature thermal energy storage and conversion systems.

14 SOLAR ENERGY↗
DOE OSTI2024

Thermal performance of phase change materials with anisotropic carbon fiber inserts

In thermal energy storage systems, phase change materials (PCMs) are widely used for thermal energy management. Most PCMs have low thermal conductivities, which limits the heat transfer rate within PCM and thus makes the phase-changing process very slow. However, thermal conductivities of PCMs can be altered by inserting targeted additives. We hypothesize that the size and shape of these additive inserts play a key role in thermal management efficiency. To this end, the impacts of carbon fiber (CF) inserts on the phase change behavior and consequent heat transfer efficiencies of inorganic and organic PCMs were investigated using experiments and simulations. Long, anisotropic CFs with high thermal conductivities formed continuous fast heat flux tunnels inside PCMs to enhance the heat transfer. Such CFs could extend the phase change fronts from the limited container-shaped interface to the larger surface of numerous CF inserts inside the PCM. These special CF inserts work with a new heat transfer mechanism, different from conventional small additives or long isotropic CF inserts. The thermal energy release rate increased by 2.5 times with 1 wt.% anisotropic CF inserts in inorganic PCM. However, CF inserts in liquid organic PCM hindered the natural convection and compromised the improved heat conduction. In conclusion, the lab-scale multiphysics simulations support these experimental observations and indicate that CF inserts have potential to enhance heat transfer in inorganic PCMs, but they are less effective in organic PCMs.

25 ENERGY STORAGE↗
DOE OSTI2025

Experimental characterization of a triply periodic minimal surface PCM-to-air thermal energy storage device

Here, the expansion of energy production has intensified research into thermal energy storage (TES) to manage variability and improve system efficiency. Heat exchanger design is critical to achieving high power densities in TES systems. This study presents a high-surface-area phase change material (PCM)-to-air heat exchanger fabricated via resin-based stereolithography with a novel gyroid-based geometry tailored for enhanced performance. Material properties of the commercial PCM and resin were characterized using analytical techniques. A controlled air loop was used to evaluate heat transfer and pressure drop at various flow rates and inlet temperatures. Results show a strong dependence on the inlet temperature difference (ΔT) relative to the PCM melting point. During charging at the highest flow rate, increasing the inlet air temperature from ΔT = 5 °C to 20 °C above the melting point increased the average heat transfer rate by 187%. During discharging, decreasing the inlet temperature by the same ΔT below the melting point led to a 232% increase. Notably, the high-surface-area design enabled nearly symmetric charging and discharging behavior, a novel result for PCM-based TES systems which are often restricted by natural convection and other effects. The overall heat transfer coefficient was calculated and compared to values from standard design correlations. The maximum thermal effectiveness reached 95% at ΔT = 20 °C and a moderate flow rate of 34 m 3 /h. Peak coefficients of performance (COP) of 7 during charging and 6.4 during discharging were observed at ΔT = 20 °C and a low flow rate of 20 m 3 /h. These results demonstrate the viability of additively manufactured geometries for advanced TES applications.

25 ENERGY STORAGE↗
DOE OSTI2022

Proper orthogonal decomposition based reduced-order modeling of flux-Limited gray thermal radiation

Here, in this work, a proper orthogonal decomposition (POD) based reduced-order model (ROM) is developed to solve gray, flux-limited thermal radiation diffusion. We focus on the variable opacity radiation penetration benchmark posed by Olson, Auer, and Hall. The T -3 relationship for opacity in conjunction with high-temperature radiation penetrating an initially cold material produces a strong thermal radiation shock. This class of problems is particularly challenging for standard POD-based reduced-order modeling due to the nonlinearities presented by 1) the T 4 source term, and 2) flux-limited diffusion operator. To address these challenges and develop a cost competitive ROM, we employ a “hyper-reduction” technique through discrete empirical interpolation (DEIM) and allow for adaptive reduced-order projections through principal interval decomposition (PID). Performance of the proposed methodology is quantified by comparing the cost savings and accuracy relative to a full-order computation. Reference solutions and snapshot data are obtained through a full-order calculation performed by the University of Chicago maintained astrophysics code, FLASH. For consistency and potential extensibility, the developed ROM is also implemented in FLASH. We find that in the initialization regime, where the thermal radiation wave is initially created by the warming of the material, this class of problems is highly reducible and suitable for POD-based ROMs. However, the strong convective nature of the wave propagation regime is less reducible and more challenging to create an efficient ROM.

42 ENGINEERING↗
DOE OSTI2024

Evaluating direct vessel injection accident-event progression of AP1000 and key figures of merit to support the design and development of water-cooled small modular reactors

The passive safety systems (PSSs) within water-cooled reactors are meticulously engineered to function autonomously, requiring no external power source or manual intervention. They depend exclusively on inherent natural forces and the fundamental principles of reactor physics, such as gravity, natural convection, and phase changes, to manage, alleviate, and avert the release of radioactive materials into the environment during accident scenarios like a loss-of-coolant accident (LOCA). PSSs are already integrated into such operating commercial reactors as the Advanced Pressurized Reactor-1000 MWe (AP1000) and the Water-Water Energetic Reactor-1200 MWe (WWER-1200) are adopted in most of the upcoming small modular reactor (SMR) designs. Examples of water-cooled SMR PSSs are the passive emergency core-cooling system (ECCS), passive containment cooling system (PCCS), and passive decay-heat removal system, the designs of which vary based on reactor system-design requirements. However, understanding the accident-event progression and phases of a LOCA is pivotal for adopting a specific PSS for a new SMR design. This study covers the accident-event progression for direct vessel injection (DVI) small-break loss-of-coolant accident (SB-LOCA), associated physics phenomena, knowledge gaps, and important figures of merit (FOMs) that may need to be evaluated and assessed to validate thermal-hydraulics models with an available experimental dataset to support new SMR design and development.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2025

A review on the state of thermal hydraulics research on air ingress scenarios in High-Temperature Gas-cooled Reactors following a D-LOFC

With the expectation of near-immediate carbon neutrality, widespread implementation of proven High-Temperature Gas-cooled Reactors (HTGRs) embodies a viable solution pathway given their inherent, passive safety features and high thermal efficiency. This study provides an overview of the current state of research involving the thermal hydraulics associated with air ingress from a depressurized loss of forced cooling (D-LOFC) in HTGRs. Accurately characterizing and predicting the physical phenomena underlying air ingress is of paramount concern, as the integrity of the fuel and core graphite support structures are threatened by the presence of oxygen. Broadly speaking, the air ingress scenario can be delineated into three main stages: (1) Depressurization, (2) Density-Driven Flow, and (3) Natural Convection. In tandem with the underlying fundamental theory, this review collates and synthesizes the existing body of contemporary research concerning the air ingress scenario following a D-LOFC. As evinced by this review, our current understanding and predictive abilities have benefited from extensive research, predominantly concentrated on the rate of air ingestion into the core. Here, additional research is necessary to holistically capture the phenomenology of an air ingress scenario following a D-LOFC by considering an additional variable: the oxygen content of the ingressing air. The latter variable requires investigation into the complex interactions of the fully integrated system. Additionally, while numerical tools are evolving domestically through the Nuclear Energy Advanced Modeling and Simulation program, a sufficiently validated code remains absent.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗