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DOE OSTI2023

Conjugate Heat Transfer Analysis in Pressurized Helium Gas Cooling Channels

Los Alamos National Laboratory (LANL) is working with NorthStar Medical Radioisotopes (NMR) on their efforts to produce Mo-99 from the irradiation of Mo-100 targets. The NMR target consists of an Inconel window that allows the electron beam to penetrate and irradiate a stack of Mo-100 disks. The irradiation process generates large amounts of heat and is cooled using pressurized helium gas flowing at 400 g/s. LANL provides both numerical analysis support and experimental support. Computational fluid dynamics (CFD) and conjugate heat transfer (CHT) analysis are performed on the NMR target to analyze the helium flow and volumetric heating through the NMR system. In this iteration of numerical analysis, we update the Mo-100 disk thickness to 0.74 mm and the gap between the Inconel window and the first disk to 0.69 mm. Estimates of the heat flux from the electron beams from Monte Carlo N-Particle code (MCNP) analysis were combined with CFD to perform the CHT analysis. The pressure drop through the targets, force applied on the first disk, beam window and target disk temperatures are some of the quantities estimated using the simulations. The pressure drop through the target was estimated as 0.198 MPa, while the force due to venturi effects across the first disk was estimated to be 100 N. The results show maximum window temperatures over 600 °C and peak disk temperatures over 1600 °C. Past work has shown that beyond 650-700 °C, the Inconel window becomes susceptible to yield and rupture. The increased temperature in these results reduces the margin of error possible on beam spot size. The disk temperatures showed a sinusoidal distribution with the 6 th – 8 th disk from each window exhibiting highest disk temperatures. The peak temperature of the stainless steel housing was close to 316 °C and that of the laminations and spacers was approximately 582 °C.

43 PARTICLE ACCELERATORS↗

NASA NTRS2016

Redesign of the Extravehicular Mobility Unit Airlock Cooling Loop Recovery Assembly

During EVA (Extravehicular Activity) 23 aboard the ISS (International Space Station) on 07/16/2013 an episode of water in the EMU (Extravehicular Mobility Unit) helmet occurred, necessitating a termination of the EVA (Extravehicular Activity) shortly after it began. The root cause of the failure was determined to be ground-processing short-comings of the ALCLR (Airlock Cooling Loop Recovery) Ion Beds which led to various levels of contaminants being introduced into the Ion Beds before they left the ground. The Ion Beds were thereafter used to scrub the failed EMU cooling water loop on-orbit during routine scrubbing operations. The root cause investigation identified several areas for improvement of the ALCLR Assembly which have since been initiated. Enhanced washing techniques for the ALCLR Ion Bed have been developed and implemented. On-orbit cooling water conductivity and pH analysis capability to allow the astronauts to monitor proper operation of the ALCLR Ion Bed during scrubbing operation is being investigation. A simplified means to acquire on-orbit EMU cooling water samples have been designed. Finally, an inherently cleaner organic adsorbent to replace the current lignite-based activated carbon, and a non-separable replacement for the separable mixed ion exchange resin are undergoing evaluation. These efforts are undertaken to enhance the performance and reduce the risk associated with operations to ensure the long-term health of the EMU cooling water circuit.

Steele, John↗

NASA NTRS2016

Redesign of the Extravehicular Mobility Unit Airlock Cooling Loop Recovery Assembly

During EVA (Extravehicular Activity) 23 aboard the ISS (International Space Station) on 07/16/2013 an episode of water in the EMU (Extravehicular Mobility Unit) helmet occurred, necessitating a termination of the EVA (Extravehicular Activity) shortly after it began. The root cause of the failure was determined to be ground-processing short-comings of the ALCLR (Airlock Cooling Loop Recovery) Ion Beds which led to various levels of contaminants being introduced into the Ion Beds before they left the ground. The Ion Beds were thereafter used to scrub the failed EMU cooling water loop on-orbit during routine scrubbing operations. The root cause investigation identified several areas for improvement of the ALCLR Assembly which have since been initiated. Enhanced washing techniques for the ALCLR Ion Bed have been developed and implemented. On-orbit cooling water conductivity and pH analysis capability to allow the astronauts to monitor proper operation of the ALCLR Ion Bed during scrubbing operation is being investigated. A simplified means to acquire on-orbit EMU cooling water samples has been designed. Finally, an inherently cleaner organic adsorbent to replace the current lignite-based activated carbon, and a non-separable replacement for the separable mixed ion exchange resin are undergoing evaluation. These efforts are undertaken to enhance the performance and reduce the risk associated with operations to ensure the long-term health of the EMU cooling water circuit.

Steele, John↗

NASA NTRS1987

Mechanical properties and morphology of poly(etheretherKetone)

Mechanical properties and morphology of poly(etheretherketone) (PEEK) were studied for samples having different thermal histories. Isothermal and rate-dependent crystallization were studied to ascertain the relationship between crystallinity/morphology and processing condition. Degree of crystallinity and microstructure were controlled by cooling the melt at different rates, ranging from quenching to slowly cooling, and by annealing amorphous material above the glass transition temperature Tg. It is found that degree of crystallinity was not as important as processing history in determining the room temperature mechanical properties. Samples with the same degree of crystallinity had very different tensile properties, depending on rate of cooling from the melt. All samples yielded by shear band formation and necked down. Quenched films had the largest breaking strains, drawing to 270 percent. Slowly cooled films exhibited ductile failure at relatively low strains. Best combined mechanical properties were obtained from semicrystalline films cooled at intermediate rates from the melt.

Cebe, Peggy↗

NASA NTRS2020

The Role of the SO2 Radiative Effect in Sustaining the Volcanic Winter and Soothing the Toba Impact on Climate

Volcanic eruptions are an important climate driver. The impact of Pinatubo-sized eruptions has been observed and is well constrained. The magnitude and duration of volcanic winter effects after super-eruptions such as Toba remain disputed due to disagreement between the strong cooling predicted by models, and much milder climate perturbations according to the paleo data. Here we present a re-evaluated climate impact of a Toba-sized super-eruption based on up-to-date GISS ModelE simulations. In this study, we account for all known primary mechanisms that govern the evolution of the volcanic plume and their nonlinear interactions. The SO2 radiative effects are evaluated for the first time in coupled climate simulations with the interactive atmospheric chemistry module. We found that SO2 effects on photochemistry, dynamics, and radiative forcing are especially prominent. Due to strong absorption in ultraviolet, SO2 feedback on photochemistry partially offsets the limiting effect associated with aerosol microphysical processes. SO2 greenhouse warming soothes the radiative cooling exerted by sulfate aerosols. SO2 absorption in the shortwave and longwave causes radiative heating and lofting of the volcanic plume, and boosts the efficiency of SO2 impact on photochemistry. Our analysis shows that SO2 lifetime and magnitude of effects scale up and increase with the amount of emitted material. For a Pinatubo-sized eruption, SO2 feedbacks on chemistry and dynamics are relevant only during the initial stage of the volcanic plume evolution, while local SO2 concentrations are high. For a Toba-sized eruption, SO2 effects are as important as sulfate aerosols, and produce a less extreme volcanic winter.

Sergey Osipov↗

NASA NTRS2011

Non-Venting Thermal and Humidity Control for EVA Suits

Future EVA suits need processes and systems to control internal temperature and humidity without venting water to the environment. This paper describes an absorption-based cooling and dehumidification system as well as laboratory demonstrations of the key processes. There are two main components in the system: an evaporation cooling and dehumidification garment (ECDG) that removes both sensible heat and latent heat from the pressure garment, and an absorber radiator that absorbs moisture and rejects heat to space by thermal radiation. This paper discusses the overall design of both components, and presents recent data demonstrating their operation. We developed a design and fabrication approach to produce prototypical heat/water absorbing elements for the ECDG, and demonstrated by test that these elements could absorb heat and moisture at a high flux. Proof-of-concept tests showed that an ECDG prototype absorbs heat and moisture at a rate of 85 W/ft under conditions that simulate operation in an EVA suit. The heat absorption was primarily due to direct absorption of water vapor. It is possible to construct large, flexible, durable cooling patches that can be incorporated into a cooling garment with this system. The proof-of-concept test data was scaled to calculate area needed for full metabolic loads, thus showing that it is feasible to use this technology in an EVA suit. Full-scale, lightweight absorber/radiator modules have also been built and tested. They can reject heat at a flux of 33 W/ft while maintaining ECDG operation at conditions that will provide a cool and dry environment inside the EVA suit.

Izenson, Mike↗

DOE OSTI2022

Solidification and grain formation in alloys: a 2D application of the grand-potential-based phase-field approach

Solidification is a significant step in the forming of crystalline structures during various manufacturing and material processing techniques. Solidification characteristics and the microstructures formed during the process dictate the properties and performance of the materials. Hence, understanding how the process conditions relate to various microstructure formations is paramount. In this work, a grand-potential-based multi-phase, multi-component, multi-order-parameter phase-field model is used to demonstrate the solidification of alloys in 2D. This model has several key advantages over other multi-phase models such as it decouples the bulk energy from the interfacial energy, removes the constraints for the phase concentration variable, and prevents spurious third-phase formation at the two phase interfaces. Here, the model is implemented in a finite-element-based phase-field modeling code. The role of various modeling parameters in governing the solidification rate and the shape of the solidified structure is evaluated. It is demonstrated that the process conditions such as temperature gradient, thermal diffusion, cooling rate, etc, influence the solidification characteristics by altering the level of undercooling. Furthermore, the capability of the model to capture directional solidification and polycrystalline structure formation exhibiting various grain shapes is illustrated. In both these cases, the process conditions have been related to the growth rate and associated shape of the dendritic structure. As a result, this work serves as a stepping stone towards resolving the larger problem of understanding the process–structure–property–performance correlation in solidified materials.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Polyethylene Blends for Improved Oxygen Barrier: Processing-Dependent Microstructure and Gas Permeability

Here this work demonstrates a greater than expected enhancement of oxygen barrier properties in linear low-density polyethylene (LLDPE)-based materials by blending LLDPE with high-density polyethylene (HDPE). The films made by melt pressing the LLDPE/HDPE blends had a greater reduction in oxygen permeability coefficients (PO 2 ) than predicted using common permeability reduction models, i.e., the harmonic average model and zero-permeability nanofiller model. The reduction of PO 2 was attributed to the presence of spherulite crystal structures, as revealed by atomic force microscopy combined with infrared spectroscopy (AFM-IR). The LLDPE matrix exhibited significant spherulite formation even at a relatively low addition of HDPEs, which likely formed tortuous pathways for diffusing oxygen molecules. Transport results from melt-pressed films contrast with the results from films with similar compositions prepared by film blowing, which did not show barrier enhancement beyond expectation. AFM-IR revealed that the blown films lacked spherulite crystals likely due to stretching in the machine direction followed by rapid cooling. These findings demonstrate the role of processing in controlling microstructures and thus the oxygen barrier performance. This work offers the possibility of achieving easily recyclable LLDPE-based packaging materials by simple blending of polyethylenes with different crystalline content.

36 MATERIALS SCIENCE↗

NASA NTRS1977

Ferrule and use thereof for cooling a melt spun hollow glass fiber as it emerges from a spinnerette

An improvement in the process of melt spinning thin walled, hollow fibers from relatively low melting glasses results if cooling of the emerging fiber is accomplished by use of a thin layer of gas to transfer heat from the fiber to a ferrule which fits closely to the spinnerette face and the individual fiber. The ferrule incorporates or is in contact with a heat sink and is slotted or segmented so that it may be brought into position around the moving fiber. Thinner walled, more uniform fibers may be spun when this method of cooling is employed.

Brown, William E.↗

DOE OSTI2024

Simulations of radiatively cooled magnetic reconnection driven by pulsed power

Magnetic reconnection is an important process in astrophysical environments, as it reconfigures magnetic field topology and converts magnetic energy into thermal and kinetic energy. In extreme astrophysical systems, such as black hole coronae and pulsar magnetospheres, radiative cooling modifies the energy partition by radiating away internal energy, which can lead to the radiative collapse of the reconnection layer. In this paper, we perform two- and three-dimensional simulations to model the MARZ (Magnetic Reconnection on Z) experiments, which are designed to access cooling rates in the laboratory necessary to investigate reconnection in a previously unexplored radiatively cooled regime. These simulations are performed in GORGON, an Eulerian two-temperature resistive magnetohydrodynamic code, which models the experimental geometry comprising two exploding wire arrays driven by 20 MA of current on the Z machine (Sandia National Laboratories). Radiative losses are implemented using non-local thermodynamic equilibrium tables computed using the atomic code Spk, and we probe the effects of radiation transport by implementing both a local radiation loss model and P 1/3 multi-group radiation transport. The load produces highly collisional, super-Alfvénic (Alfvén Mach number M A ≈ 1.5), supersonic (Sonic Mach number M S ≈ 4–5) strongly driven plasma flows which generate an elongated reconnection layer (Aspect Ratio L/δ≈100 , Lundquist number S L ≈ 400). The reconnection layer undergoes radiative collapse when the radiative losses exceed the rates of ohmic and compressional heating (cooling rate/hydrodynamic transit rate = τ$^{–1}_{cool}$/τ$^{–1}_{H}$ ≈100); this generates a cold strongly compressed current sheet, leading to an accelerated reconnection rate, consistent with theoretical predictions. Lastly, the current sheet is also unstable to the plasmoid instability, but the magnetic islands are extinguished by strong radiative cooling before ejection from the layer.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2021

Isotherm, Kinetic, Process Modeling, and Techno-Economic Analysis of a Diamine-Appended Metal-Organic Framework for CO 2 Capture Using Fixed Bed Contactors

In this report, diamine-appended metal-organic frameworks exhibiting step-shaped CO 2 adsorption are exceptional candidates for energy-efficient carbon capture. However, there are few studies examining their performance in real-world capture scenarios, in part due to the challenge inherent in modeling their CO 2 uptake behavior. Here, we develop a dual-site Sips model to fit experimental CO 2 adsorption data for dmpn-Mg 2 (dobpdc) (dmpn = 2,2-dimethyl-1,3-diaminopropane; dobpdc 4- = 4,4'-dioxidobiphenyl-3,3'-dicarboxylate) and develop a linear driving force model for the adsorption kinetics based on available experimental data. These models are used to develop a dynamic, fixed bed, nonisothermal contactor model using shaped particles of the material, which is validated with experimental breakthrough data. We also examine the effects of the high heat of adsorption of the material on CO 2 uptake performance and find that heat removal is essential to maximize capture performance. We finally investigate "basic"(no bed cooling during adsorption) and "modified"(bed cooling during adsorption) temperature swing adsorption (TSA) processes using dmpn-Mg 2 (dobpdc), and their process economics are compared to a state-of-the-art monoethanolamine (MEA) capture system with and without heat recovery. In the absence of heat recovery, the adsorbent systems are more costly than established technology. However, with 85% heat recovery, both adsorbent-based TSA processes are projected to cost less than the MEA system. This work highlights that thermal management is vital for implementation of dmpn-Mg 2 (dobpdc) as a viable CO 2 capture technology. Investigation of other contactor technologies that can provide unique ways to manage system heat represent promising future areas of study.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

Comparing energy and water use of aqueous and gas-based metalworking fluids

Gas-based metalworking fluids (MWFs) have been proposed as alternative coolants and lubricants in machining operations to mitigate concerns surrounding water use and pollution, industrial hygiene, occupational health, and performance limitations associated with water-based (aqueous) MWFs that are ubiquitously used in the metals manufacturing industry. This study compares the primary energy and water use associated with the consumptive use, delivery, and disposal of aqueous MWFs with three gas-based MWFs in the literature-minimum quantity lubricant-in-compressed air (MQL), liquid/gaseous N-2, and liquid/supercritical CO2. The comparison accounts for reported differences in machining performance in peer-reviewed experimental studies across several machining processes and materials. The analysis shows that despite the reported improvement in tool life with N-2 and CO2-based MWFs, the electricity- and water-intensive separation and purification processes for N-2 and CO2 lead to their higher primary energy and water use per volume of material machined relative to water-based MWFs. Although MQL is found to have lower primary energy use, significant consumptive water use associated with the vegetable oil commonly used with this MWF leads to higher overall water use than aqueous MWF, which is operated in a recirculative system. Gas-based MWFs thus shift the water use upstream of the manufacturing plant. Primary energy and water use of gas-based MWFs could be reduced by focusing on achieving higher material removal rates and throughput compared to aqueous MWF instead of solely targeting improvements in tool life. Additionally, the consumptive use of CO2 and N-2 MWFs could be minimized by optimizing their flow rates and delivery to precisely meet the cooling and lubrication needs of specific machining processes instead of flooding the tool and workpiece with these gases. This article met the requirements for a gold-gold JIE data openness badge described at http://jie.click/badges.

cutting fluids↗

DOE OSTI2020

Convenient analytical formula for cluster mean diameter and diameter dispersion after nucleation burst

Here, we propose an alternative method of estimating the mean diameter and dispersion of clusters of particles, formed in a cooling gas, right after the nucleation stage. Using a moment model developed by Friedlander [S. K. Friedlander, Ann. N. Y. Acad. Sci. 404, 354 (1983)], we derive an analytic relationship for both cluster mean diameter and diameter dispersion as a function of two of the characteristic times of the system: the cooling time and the primary constituents collision time. These formulas can be used to predict diameter and dispersion variation with process parameters, such as the initial primary constituents' concentration or cooling rate. It is also possible to use them as an input to the coagulation stage, without the need to compute complex cluster generation during the nucleation burst. We compared our results with a nodal code (NGDE) and got excellent agreement.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2020

Optimization of Window Positions for Wind-Driven Natural Ventilation Performance

This paper optimizes opening positions on building facades to maximize the natural ventilation’s potential for ventilation and cooling purposes. The paper demonstrates how to apply computational fluid dynamics (CFD) simulation results to architectural design processes, and how the CFD-driven decisions impact ventilation and cooling: (1) background: A CFD helps predict the natural ventilation’s potential, the integration of CFD results into design decision-making has not been actively practiced; (2) methods: Pressure data on building facades were obtained from CFD simulations and mapped into the 3D modeling environment, which were then used to identify optimal positions of two openings of a zone. The effect of the selected opening positions was validated with building energy simulations; (3) results: The cross-comparison study of different window positions based on different geographical locations quantified the impact on natural ventilation effectiveness; and (4) conclusions: The optimized window position was shown to be effective, and some optimal solutions contradicted the typical cross-ventilation strategy.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

NASA NTRS1992

Physical processes within the nocturnal stratus-topped boundary layer

There are many physical processes involved in the stratus-topped boundary layer: longwave radiation cooling, entrainment, latent heating, surface heating, solar heating, and drizzling, for example. The manner in which the processes combine to maintain the turbulence within the stratus-topped boundary layer remains an unsolved problem. The large eddy simulation technique is used to examine the first four physical processes mentioned above. First, the contribution of each physical process to the thermodynamic differences between the updraft and downdraft branches of turbulent circulations is examined through a conditional sampling. Second, these mean thermodynamic differences are shown to express well the vertical distributions of heat and moisture fluxes within stratus-topped boundary layers. These provide a method to validate the process partitioning technique. (This technique assumes that the net flux profile can be partitioned into different component-flux profiles according to physical processes, and that each partitioned component flux is linear in height.) In this paper, the heat and moisture fluxes are process partitioned, and each component-flux is found to contribute to the net flux in a way that is consistent with its corresponding process contribution to the mean thermodynamic differences between updrafts and downdrafts. Also, the net flux obtained by summing all component-fluxes agrees very well with that obtained directly from the large-eddy simulations.

Moeng, Chin-Hoh↗

DOE OSTI2024

Analysis of heat and mass transfer potential of a dew-point cooling tower in different climatic conditions

In this study, the performance of the Dew-Point Cooling Tower (DPCT) was analyzed for different factors in a variety of climate conditions. For this purpose, a dedicated numerical model describing heat and mass transfer processes was developed and validated. The results of the numerical simulations allowed to analyze the potential of utilizing the heat and mass transfer process with the dew-point phenomenon for water cooling. It was established that the operational parameters that have a high impact on the performance of the DPCT are: inlet water temperature and inlet air humidity ratio. It was also established that DPCT achieves the highest COP and Specific Cooling Capacity for cold subtropical highland climates and that it achieves highest Wet-bulb Effectiveness for monsoon-influenced humid subtropical climates. In conclusion, the regions where all the efficiency factors achieved above-average values included warm, arid, and desert climates.

42 ENGINEERING↗

DOE OSTI2026

Final report: Insights from ARM observations into aerosol processing and transport by extratropical cyclones and aerosol effects on cyclone clouds

This project advanced understanding of aerosol–cloud interactions in extratropical cyclones using observations from the Atmospheric Radiation Measurement (ARM) Eastern North Atlantic (ENA) observatory and ACE-ENA field campaigns, along with satellite datasets and numerical modeling. We have quantified the susceptibility of frontal clouds to aerosols, showing that this susceptibility is similar to that in non-frontal clouds despite substantial (factor 2) differences in droplet concentrations between these cloud types, and also significant differences in cloud albedo. A key finding was that Aitken-mode (here, 60-100nm diameter) aerosols play a disproportionately important role in droplet activation in frontal clouds, and concentrations of these particles are frequently strongly biased in climate models. Activation of aerosols depends strongly on updraft speeds, and via collaboration with Argonne National Laboratory we contributed to quantifying these better with the ARM radar wind profiler at the ENA site. Our studies in the North Atlantic have analogs in the Southern Ocean, and to draw these out we examined data from the MARCUS and SOCRATES field campaigns. We identified new particle formation within extratropical cyclones as a potentially important source of cloud condensation nuclei in these pristine marine environments. By combining ARM observations with perturbed parameter ensemble simulations, we demonstrated that surface observations can effectively constrain aerosol–cloud adjustments and reduce uncertainty in simulated cloud liquid water path responses by approximately 15%, yielding stronger constraints on historical aerosol cooling effects. The work further established precipitation processes as a dominant control on aerosol–cloud interactions and Earth system predictability.

Gordon, Hamish [Department of Chemical Engineering↗

NASA NTRS2007

Effects of Thermal Barrier Coatings on Approaches to Turbine Blade Cooling

Reliance on Thermal Barrier Coatings (TBC) to reduce the amount of air used for turbine vane cooling is beneficial both from the standpoint of reduced NOx production, and as a means of improving cycle efficiency through improved component efficiency. It is shown that reducing vane cooling from 10 to 5 percent of mainstream air can lead to NOx reductions of nearly 25 percent while maintaining the same rotor inlet temperature. An analysis is given which shows that, when a TBC is relied upon in the vane thermal design process, significantly less coolant is required using internal cooling alone compared to film cooling. This is especially true for small turbines where internal cooling without film cooling permits the surface boundary layer to remain laminar over a significant fraction of the vane surface.

Boyle, Robert J.↗