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At least 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Flow instabilities in helical-coil steam generators for small modular reactors: A review

Here, this study covers the research and discoveries in two-phase flow-boiling instabilities available in the literature—specifically for a helical-coil steam generator (HCSG), including experimental findings, theoretical research, computational models, and system code analyses—supporting research and development of representative small modular reactors (SMRs). Like other new and advanced reactor systems, water-cooled SMRs require experimental data from both integral and separate thermal-hydraulics test facilities for the verification and validation (V&V) of the computational models and computer codes in order to design and obtain regulatory approval. The complex dynamics of two-phase flow-boiling instabilities includes flow regimes physics phenomena, flow-channel geometries, heat-transfer behavior, and interactions among the solid–liquid-gas within the system boundary, all of which are pivotal for understanding the design and operational challenges of SMRs. This study focuses on identifying the relevant knowledge gaps on boiling instabilities—specifically for a HCSG—and provides insights about future research direction optimizing the transport of thermal energy, mass-flow rates, and boundary conditions that ensure the adequate heat-transfer performance, operational stability, and safety associated with SMR systems.

20 FOSSIL-FUELED POWER PLANTS↗
NASA NTRSDate not supplied

Experimental, Computational, Theoretical and Analytical Investigation of Flow Boiling in Reduced Gravity

Two-phase thermal management systems are far superior to their single-phase counterparts because of their ability to capitalize on the coolant’s both sensible and latent heats, thereby yielding orders of magnitude higher heat transfer coefficients and smaller system footprints. A vital knowledge necessary for their implementation in future space systems is performance in microgravity. Long-duration microgravity experiments are necessary to obtain reliable databases, which would then be used to build reliable predictive tools. To achieve this goal, investigators at the Purdue University Boiling and Two-Phase Flow Laboratory (PU-BTPFL) and the NASA Glenn Research Center (NASA-GRC) have been collaborating towards the development of the Flow Boiling and Condensation Experiment (FBCE) and eventual execution onboard the International Space Station (ISS). FBCE has now matured to a point where it is ready for transport to the ISS, where first tests will be conducted using the Flow Boiling Module (FBM). In preparation for the ISS tests, a series of pre-launch Mission Sequence Tests (MSTs) was performed at GRC in Earth gravity with FBM mounted in a vertical upflow orientation using n-perfluorohexane as working fluid. The pre-launch tests included variations of flow rate, surface heat flux, inlet conditions, and both single-sided and double-sided wall heating. This presentation will summarize experimental results from these tests as well as both analytic and theoretical tools for prediction of two-phase heat transfer coefficient and critical heat flux (CHF). Also discussed will be an assessment of predictive accuracy of these tools against the experimental data.

Mission Sequence tests↗
NASA NTRSDate not supplied

Acoustic Insights into Flow Condensation Mechanisms

Two-phase thermal management systems, with both boiling and condensation processes, offer great potential and heat transfer coefficients that are orders of magnitude higher than traditional single-phase systems. However, two-phase flows can suffer from a wide range of interfacial instabilities leading to significant thermal performance degradation. In this study, we aim to detect regime transitions and characterize dominating physical mechanisms of flow condensation, such as turbulent diffusion in annular liquid film and interfacial waves, using an integrated system of acoustic, modal, and optical sensing techniques and thermofluidic characterizations. A wideband acoustic emissions sensor and high-sensitivity accelerometer are utilized to capture acoustic and vibrational signatures that signal the onset of liquid film formation and interfacial waves during flow pattern transitions. Compared to optical imaging, wideband acoustic emission sensing allows for higher sampling rates to capture high-frequency interface oscillations critical to the flow regime transitions and works well even for condensation in opaque tubes. Acoustic features (e.g., amplitude, frequency, energy, duration) are correlated with thermofluidic processes (e.g., capillary flows, turbulent flows, boiling, condensation). By relating thermal performance metrics with these dynamic signatures in acoustic and modal regimes, we explore the ability to probe and monitor critical flow regime transitions and transport efficiency in flow condensation.

Acoustic Modal Regimes↗
DOE OSTI2021

A phase-field method for boiling heat transfer

Here we present a phase field method for heat transfer in two-phase flow with boiling. The vapor/liquid interface evolution is modeled by the Cahn-Hilliard equation. The phase change rate is determined by accounting for the heat conduction balance on either vapor or liquid side of the interfacial area, depending on which side the temperature is assumed to be maintained at the saturation temperature during boiling. The velocity correction scheme proposed by Dong & Shen [27] is extended to solve the Navier-Stokes equations for a non-solenoidal velocity field, and the entropy viscosity method is employed for stabilization. The phase change model is verified by two-dimensional simulations of a vapor bubble growing in super-heated liquid and in film boiling. In both cases, mesh independence of the results is systematically performed. Subsequently, the method is applied to predict the growth of three-dimensional vapor bubble in a rectangular microchannel with boiling flow, achieving good agreement with experimental measurements and available simulation results using the level-set method. The numerical experiments demonstrate that the required mesh resolution for the phase field method is comparable with that of volume of fluid (VoF) and level-set methods.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2017

Newton-Krylov method in solving drift-flux two-phase flow problems for both pre-CHF and post-CHF conditions at steady state

Furthermore, this paper presents numerical simulations of two-phase flow heat transfer for both pre-CHF and post-CHF conditions typical in light water nuclear reactors. The conjugate heat transfer problem is modeled with one-dimensional drift-flux two-phase flow model for coolant flow and two-dimensional heat conduction equation in solid walls. Fully implicit time integration schemes were employed, and the resulted non-linear equations were solved with a Newton-Krylov method. For the drift-flux two-phase flow model, the EPRI drift-flux closure correlation is used to model the relative motion between the two phases. Additional closure correlations were adopted from REALP5-3D to determine two-phase flow regime, wall boiling heat and mass transfer, interfacial heat and mass transfer, and two-phase flow frictional pressure drop. Three sets of experiments were used for code validation, including Bartolomei subcooled flow boiling in vertical pipes, FRIGG boiling tests in vertical bundles, and Bennett heated tube tests. RELAP5-3D simulation results were also provided to perform code-to-code benchmark. Overall, numerical results of this work showed good agreements with both experimental data and RELAP5-3D simulation results. Discrepancy between them were also identified in post-CHF region, which suggests necessary further improvement.

42 ENGINEERING↗
NASA NTRS1990

An improved method for simultaneous determination of frictional pressure drop and vapor volume fraction in vertical flow boiling

The two-phase frictional pressure drop and vapor volume fraction in the vertical boiling and adiabatic flow of the refrigerant, R11, have been simultaneously measured by a liquid balancing column and differential magnetic reluctance pressure transducers. An account is given of the experimental apparatus and procedure, data acquisition and analysis, and error estimation employed. All values of two-phase multipliers evaluated on the basis of the measured frictional pressure drop data in vertical upflow fall in the range bounded by the predictions of the Chisholm correlation and the homogeneous model.

Klausner, J. F.↗
DOE OSTI2021

Study of the film boiling heat transfer and two-phase flow interface behavior using image processing

Here, in this study, based on a small-scale quench test facility, the two-phase flow interface behavior during quench transients is visualized and analyzed utilizing an image processing framework. The high-fidelity experimental results obtained for two-phase flow in the current framework can support various studies both in the time domain and in the frequency domain. In particular, visualization of the data obtained from different heating surfaces under different test conditions are used to perform a full-scale transient 2-D vapor film reconstruction. The liquid-vapor interface variations in various heat transfer regimes as well as at the initial film breakup point can be directly obtained through the processed data. Moreover, the temporal variation of the interfacial wave frequency approaching quench is investigated in detail. Based on the high-resolution data obtained for the liquid-vapor interface, the detailed phase velocity and temperature profiles are obtained through theoretic analysis, based on which the film boiling heat transfer coefficient (HTC) can be determined. In addition, an improved film boiling HTC model is developed considering the effects of wall superheat, liquid subcooling temperature, vapor film thickness as well as fluid properties. The model is found to predict film boiling HTC well within 15% error.

42 ENGINEERING↗
NASA NTRSDate not supplied

CFD Predictions of Boiling Regime Transitions during Line Chilldown validated against a 1G LN2 Experiment

Introduction Before filling a propellant tank on the ground or in Space, the transfer line between the donor and receiver tanks must be cooled down preferably by sacrificing a minimum amount of the cryogenic fluid. The cryogenic line chill-down process involves a transition between different flow boiling regimes, namely, film boiling, transition film boiling, and nucleate boiling which are complex and may be quite gravity-dependent. Capturing these boiling phenomena and predicting the transition between them in a CFD framework is new and challenging both for 1g and microgravity applications. Materials & Methods The present work addresses this challenge by employing a two-phase Eulerian approach in the context of a homogeneous fluid mixture together with the Lee phase change model to capture the film boiling regime of the chill-down process using ANSYS Fluent®. The nucleate boiling regime is predicted by incorporating an in-house developed sub-grid model that accounts for bubble nucleation, bubble growth, bubble departure diameter, and their shedding frequency. The sub-grid model is encoded and implemented into Fluent via a user-defined function for the wall-fluid heat flux calculations. The mathematical formulation and numerical implementation of the CFD model are described in detail. The coupled CFD-Subgrid model is validated against published experimental data for liquid nitrogen chill-down of a heated stainless-steel pipe in 1g. Results Numerical simulation results show good agreements between the CFD predictions of the wall temperature evolution, rewetting temperature, and transition between film and nucleate boiling, with the experimental measurements published by Darr et al [2] for several different LN2 flowrates in the vertical pipe orientation. The CFD predictions for the wall temperature distribution indicate a rapid quenching of the wall at two upstream and downstream temperature sensing locations as compared to the experimental measurement. The only tuning parameter in the CFD model is the Lee mass transfer coefficient. The CFD Model predicts the Liedenfrost rewetting temperature in close agreement with the experiment. This marks a transition between stable and transitionary flow boiling regimes. The CFD-predicted boiling curve for the downstream sensor location is also compared against its experimental counterpart and indicates that the model is able to predict all the key temperature and heat flux parameters during the transitions from stable to transitionary film boiling to nucleate boiling in close agreement with the experiment. A sequence of predicted volume fraction, and temperature contours depicting these transitions will be presented.

Evaporation Condensation↗
NASA NTRSDate not supplied

Predictions of Line Chilldown Boiling Regime Transitions by a Coupled CFD-Sub-Grid Boiling Model Validated against 1G LN2 Experiments

Propellant storage and transfer during future long-duration missions will involve fuel depot operations in which a donor depot tank is used to fill a receiver spacecraft tank with a cryogenic propellant. Prior to the on-Orbit filling operation both the receiver tank and the transfer line must be cooled. The line chilldown process involves transition between boiling regimes in microgravity that will be quite different from their 1g ground-based counterparts. Since the cryogenic propellant itself will be used to perform the chilldown process, the time constants to cool the wall and the amount of fuel that will be used become important design considerations. In this light, the focus of the present work is to capture the flow boiling characteristics of a cryogenic fluid, namely, liquid nitrogen, during the chill-down of a transfer line using CFD modelling and simulations. The cryogenic chill-down process involves different flow boiling regimes: film boiling, transition boiling and nucleate boiling. The prediction of transition between these regimes in a CFD framework is new and challenging. The present work addresses this challenge by employing a volume-of-fluid (VOF) based methodology with Lee phase change model to predict the film boiling regime of the chill-down process in ANSYS Fluent®. The transition and nucleate boiling regimes are predicted by incorporating a sub-grid model that accounts for bubble nucleation, growth, shedding frequency, and departure diameter. The sub-grid model is implemented into Fluent via a user-defined function for wall-fluid heat flux calculations. The sub-grid model is similar in formulation to the well-known Rensselaer Polytechnic Institute (RPI) boiling model. The CFD model is validated against published experimental data for liquid nitrogen chill-down of a heated stainless-steel pipe in 1g. Predicted results shows good agreement of wall temperature, rewetting temperature, and transition between film and nucleate boiling with the experimental measurements for several different LN2 flowrates in the vertical orientation. The strengths and weaknesses of this modeling approach are presented and discussed.

Cryogenic Fluid Management↗
NASA NTRS2023

Validation of Universal Cryogenic Flow Boiling Correlations in Thermal Desktop for Liquid Helium

Understanding two-phase cryogenic propellant behavior is key to enabling technologies for future spaceflight missions. Developing accurate models of two-phase flow phenomena, particularly flow boiling in the heating configuration is relevant to the propellant transfer process both in microgravity and on other planetary surfaces. Currently there is a need for more accurate, direct cryogenic data anchored models for various boiling phenomena. Recently, universal correlations for cryogens flowing in heated tubes have been developed for a wide variety of fluids, thermodynamic conditions, and various regimes across the boiling curve, and have been patched to provide a smooth, continuous predictive curve. This paper demonstrates how these correlations have been ported into Thermal Desktop to improve predictive performance. To test the validity of the new correlations, Thermal Desktop is validated against a historical dataset of flow boiling experiments in the heating configuration using liquid helium. Based on results, the new correlations show a substantial improvement over the original built-in flow boiling correlations in Thermal Desktop in predicting the wall temperature as a function of preponderant parameters for this quantum fluid.

cryogenic propellant transfer↗
DOE OSTI2015

DNS of turbulent flow with hemispherical wall roughness

The present study of the effect of roughness density on the mean flow turbulence parameters is motivated by the need for new generation of boundary conditions for multiphase computational multiphase fluid dynamics (CMFD) models applied to boiling flows. Effect of roughness element density on the turbulent flow in a channel is quantified through direct numerical simulations (DNSs). The Navier--Stokes equations are solved using finite element method and bubbles are approximated as rigid near-hemispherical obstacles at the wall. Six different cases were analysed including channel flow with smooth wall and channel flow with rough wall for five different bubble nucleation site densities. Friction factor and the law of the wall was calculated and compared with the previously published results. Existing correlations for nucleating bubble site density dependency on a wall heat flux were used to obtain a relation between the heat flux and the friction factor, leading to the law of the wall dependency on the heat flux. This separate effect study provides new guidelines on how the heat flux in subcooled boiling regime affects the turbulence behaviour near the wall and guides the computational fluid dynamics model development for boiling two-phase flows.

Mechanics↗
NASA NTRS2023

Effects of Heating Configuration and Operating Parameters on Heat Transfer and Interfacial Physics of Microgravity Flow Boiling With Subcooled Inlet Conditions –Experiments Onboard the International Space Station

This study is part of the Flow Boiling and Condensation Experiment (FBCE), a collaborative effort between the Purdue University Boiling and Two-Phase Flow Laboratory (PU-BTPFL) and the NASA Glenn Research Center. The FBCE fitted with the Flow Boiling Module (FBM) was launched to the International Space Station (ISS) in August 2021 and experiments were successfully performed from February to July 2022 to amass a large microgravity-flow-boiling database. This study is focused on heat transfer and flow visualization of microgravity flow boiling of n-Perfluorohexane in a rectangular channel of 5.0 mm height, 2.5 mm width (heated), and 114.6 mm length, with subcooled inlet conditions. High-speed-video photography is utilized to present flow patterns and temporal interfacial behavior. Heat transfer results are presented in the form of flow boiling curves and both parametric curves and streamwise profiles of wall temperature and heat transfer coefficient. Firstly, the parametric effects of mass velocity (199.4 – 3200.0 kg/m 2 s), inlet subcooling (0.2 – 46.0°C), and inlet pressure (124.2 – 176.7 kPa), on the aforementioned aspects are assessed for double-sided heating to establish them for a microgravity environment. Of these three parameters, mass velocity and inlet subcooling mostly determine the microgravity flow boiling behavior, while inlet pressure plays an insignificant role. Flow patterns for double-sided heating are more complex than those for single-sided heating due to interaction between the two vapor layers. Vapor interaction is minimized at high subcoolings and high mass velocities due to strong condensation offered by the subcooled bulk liquid layer separating them. Despite the different flow patterns, both single- and double-sided heating generally result in similar parametric trends and local heat transfer coefficients for similar operating conditions. Flow instabilities manifest as temporal flow anomalies and temperature oscillations, and their severity increases with increasing boiling number. Secondly, the effects of heating configuration are analyzed by comparing and contrasting several aspects of single- and double-sided heating data. The heat fluxes at which onset of nucleate boiling degradation (ONBD) and critical heat flux (CHF) occur are distinctly different for single- and double-sided heating. There exists a threshold inlet subcooling demarcating the dominance of flow acceleration and condensation effects in vapor removal from the near-wall region and replenishment of fresh liquid for boiling. Above the threshold, condensation from the near-wall region is dominant and single-sided heating yields higher heat fluxes, and below it, acceleration is dominant and double-sided yields higher heat fluxes. At mass velocity in the range of 200 – 2400 kg/m 2 s, the threshold inlet subcooling lies in the approximate range of 20 – 30°C (corresponding inlet quality of roughly -0.40 – -0.20).

Microgravity↗
DOE OSTI2016

High Fidelity BWR Fuel Simulations

This report describes the Consortium for Advanced Simulation of Light Water Reactors (CASL) work conducted for completion of the Thermal Hydraulics Methods (THM) Level 3 milestone THM.CFD.P13.03: High Fidelity BWR Fuel Simulation. High fidelity computational fluid dynamics (CFD) simulation for Boiling Water Reactor (BWR) was conducted to investigate the applicability and robustness performance of BWR closures. As a preliminary study, a CFD model with simplified Ferrule spacer grid geometry of NUPEC BWR Full-size Fine-mesh Bundle Test (BFBT) benchmark has been implemented. Performance of multiphase segregated solver with baseline boiling closures has been evaluated. Although the mean values of void fraction and exit quality of CFD result for BFBT case 4101-61 agreed with experimental data, the local void distribution was not predicted accurately. The mesh quality was one of the critical factors to obtain converged result. The stability and robustness of the simulation was mainly affected by the mesh quality, combination of BWR closure models. In addition, the CFD modeling of fully-detailed spacer grid geometry with mixing vane is necessary for improving the accuracy of CFD simulation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2012

Energy Efficient Electronics Cooling Project

Parker Precision Cooling Business Unit was awarded a Department of Energy grant (DE-EE0000412) to support the DOE-ITP goal of reducing industrial energy intensity and GHG emissions. The project proposed by Precision Cooling was to accelerate the development of a cooling technology for high heat generating electronics components. These components are specifically related to power electronics found in power drives focused on the inverter, converter and transformer modules. The proposed cooling system was expected to simultaneously remove heat from all three of the major modules listed above, while remaining dielectric under all operating conditions. Development of the cooling system to meet specific customer's requirements and constraints not only required a robust system design, but also new components to support long system functionality. Components requiring further development and testing during this project included pumps, fluid couplings, cold plates and condensers. All four of these major categories of components are required in every Precision Cooling system. Not only was design a key area of focus, but the process for manufacturing these components had to be determined and proven through the system development.

42 ENGINEERING↗
NASA NTRS1976

Heat Transfer and Fluid Mechanics Institute, Meeting, 25th, University of California, Davis, Calif., June 21-23, 1976, Proceedings

Major research advances in heat transfer and fluid dynamics are outlined, with particular reference to relevant energy problems. Of significant importance are such topics as synthetic fuels in combustion, turbulence models, combustion modeling, numerical methods for interacting boundary layers, and light-scattering diagnostics for gases. The discussion covers thermal convection, two-phase flow and boiling heat transfer, turbulent flows, combustion, and aerospace heat transfer problems. Other areas discussed include compressible flows, fluid mechanics and drag, and heat exchangers. Featured topics comprise heat and salt transfer in double-diffusive systems, limits of boiling heat transfer in a liquid-filled enclosure, investigation of buoyancy-induced flow stratification in a cylindrical plenum, and digital algorithms for dynamic analysis of a heat exchanger. Individual items are announced in this issue.

Mckillop, A. A.↗
NASA NTRS2018

Two-Phase Flow System Design Status of the Flow Boiling and Condensation Experiment

The Flow Boiling and Condensation Experiment (FBCE) is a flight experiment that is designed to operate in the Fluids Integrated Rack (FIR) on the International Space Station (ISS). The goal of the FBCE is to obtain heat transfer data, as well as general flow data, for two-phase flow systems in microgravity. This will help in the design of thermal management systems that are able to utilize latent heat transfer more efficiently.

deFiebre, Jesse↗