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DOE OSTI2022

Influence of design and operating parameters for additively manufactured intensified packing devices on CO 2 -Absorption column cooling and capture efficiency

Solvent-based CO 2 absorption is technologically a matured CO 2 capture pathway but suffers from: high regeneration energy demand, and solvent temperature rise and decreased capture efficiency caused by the heat of reaction. While research has focused on developing non-aqueous and low-aqueous solvents for decreasing the regeneration energy, the temperature bulge due to exothermic absorption is typically dealt with by cooling the solvent with an external inter-stage heat-exchanger. This approach may increase the overall process footprint, as well as capital and operating costs. Here, the current study explores a process intensification approach by incorporating inside the column an additively manufactured intensified packing device that consists of corrugated plates and internal coolant channels. The corrugated plates provide surface area for mass transfer between gas and liquid, while cooling fluid inside the internal channels removes heat from the exothermic reactive system. Two different intensified devices with specific surface areas of 266 m 2 /m 3 and 359 m 2 /m 3 were designed, manufactured, and tested inside a 2.06-m long and 0.203-m diameter column packed with commercial Mellapak 250Y packing. The device with a lower surface area showed up to 27 % reduction in cooling performance. A steady-state heat transfer model provides good agreement with the experimental column temperature and intra-stage heat removal data. Although a decrease in heat transfer performance was observed for the device with lower surface area, CO 2 capture experiments performed with simulated flue gas and low-aqueous solvent demonstrated that both intensified devices lead to a similar improvement of 12 % in capture efficiency. This study provides an understanding on simplifying the intensified packing device geometry and decreasing the device fabrication cost by 25 % without compromising with the CO 2 absorption performance of the packed column.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Benchmark Specification for FFTF LOFWOS Test #13

The Fast Flux Test Facility (FFTF) at the Hanford site in Washington was designed by the Westinghouse Electric Corporation for the U.S. Department of Energy. FFTF was a 400 MW thermal, oxide-fueled, liquid sodium cooled test reactor, built to assist development and testing of advanced fuels and materials for fast breeder reactors. After reaching criticality in 1980, FFTF operated until 1992, providing the U.S. Department of Energy (DOE) with the means to test fuels, materials, and other components in a fast neutron flux environment. In July 1986, a series of unprotected transients (with the plant protection system intentionally disabled) were performed in FFTF as part of the passive safety demonstration program. Among these were thirteen loss of flow without scram (LOFWOS) tests. The goals of this program included confirming the liquid metal reactor safety margins, providing data for computer code validation, and demonstrating the inherent and passive safety benefits of specific design features. The test defined in this benchmark is LOFWOS Test #13, which was initiated at 50% power and 100% flow with the pump pony motors turned off. This benchmark specification is intended to support collaborative efforts within international partnerships on the validation of simulation tools and models in the area of Sodium-cooled Fast Reactor (SFR) safety. Validated tools and models are needed to evaluate SFR inherent safety characteristics and assess the impact of passive design features in response to accident initiators. Comparisons with experimental data and the results of safety analyses from other groups create unique opportunities to improve predictive capabilities of computational codes and methods for SFR modeling and simulation. The conditions of the LOFWOS test along with the feedback from FFTF’s limited free bow core restraint system and the novel passive reactivity control Gas-Expansion Modules (GEMs) pose a very challenging and uniquely valuable benchmark exercise.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

NASA NTRS2014

Spacesuit Water Membrane Evaporator; An Enhanced Evaporative Cooling Systems for the Advanced Extravehicular Mobility Unit Portable Life Support System

Spacesuit Water Membrane Evaporator - Baseline heat rejection technology for the Portable Life Support System of the Advanced EMU center dot Replaces sublimator in the current EMU center dot Contamination insensitive center dot Can work with Lithium Chloride Absorber Radiator in Spacesuit Evaporator Absorber Radiator (SEAR) to reject heat and reuse evaporated water The Spacesuit Water Membrane Evaporator (SWME) is being developed to replace the sublimator for future generation spacesuits. Water in LCVG absorbs body heat while circulating center dot Warm water pumped through SWME center dot SWME evaporates water vapor, while maintaining liquid water - Cools water center dot Cooled water is then recirculated through LCVG. center dot LCVG water lost due to evaporation (cooling) is replaced from feedwater The Independent TCV Manifold reduces design complexity and manufacturing difficulty of the SWME End Cap. center dot The offset motor for the new BPV reduces the volume profile of the SWME by laying the motor flat on the End Cap alongside the TCV.

Bue, Grant C.↗

DOE OSTI2022

Zero Liquid Discharge and Water Reuse in Recirculating Cooling Towers at Power Facilities: Review and Case Study Analysis

Zero liquid discharge (ZLD) systems installed at power facilities with the primary purpose of meeting water discharge regulations have the added benefit of providing high quality effluent that can be reused in the facility. This paper provides a review of water use in power sector recirculating cooling towers and a baseline assessment of on-site water reuse at natural gas combined cycle (NGCC) power facilities. Two NGCC facilities with reverse-osmosis (RO) or brine-concentrator processes followed by evaporation ponds were selected as case studies; data from these facilities were used to quantify the water, energy, and cost implications of implementing conventional and emerging ZLD technologies. At one case study facility, model results show that implementation of ZLD would reduce water withdrawals by 18%, which is less than savings associated with implementation of dry cooling but comparable to current efforts to reduce water withdrawals by increasing cycles of concentration. Implementation of ZLD using high-recovery RO resulted in a doubling of the levelized cost of water (LCOW). LCOW increased more when a brine concentrator was used. For both case studies, the ZLD system using high-recovery RO required less than 0.1% of a facilitiy's annual electricity generation and the ZLD system using a brine concentrator process required less than 0.8%. Additionally, increasing the evaporation pond area to minimize required ZLD system recovery rates and reduce system electricity costs does not reduce the LCOW. Instead, the LCOW increases because less water is recovered and more water is lost to evaporation. Furthermore, if water availability decreases or water competition/cost increases, facilities may be incentivized to maximize water recovery from ZLD systems.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

Operational Experience of the NML Cryogenic Plant at the FAST Test Facility

The NML cryogenic plant cools two individually cryostated superconducting radio frequency (SRF) capture cavities and one prototype ILC cryomodule with eight SRF cavities. This complex accelerates electrons at 150 MeV for the Integrable Optics Test Accelerator (IOTA) ring, located at the Fermilab Accelerator Science and Technology (FAST) facility. The cryogenic plant is composed of two nitrogen precooled Tevatron satellite refrigerators, two Mycom 2016C compressors, a cryogenic distribution system, a Frick purifier compressor, two charcoal bed adsorber purifiers, and a liquid ring vacuum pump with a roots booster. The SRF cavities are immersed in a 2.0 K liquid helium bath, shielded with a 5 K gaseous helium shield and a liquid nitrogen cooled thermal shield. Since 2019, this R&D accelerator complex has gone through four science runs with an average duration of 12 months. Operational experience for each run, availability metrics, performance data and common outages are presented in this paper.

Wallace, Timothy [Fermilab] (ORCID:000900051589302↗

NASA NTRS1974

Improved thermoelectrically cooled quartz crystal microbalance

Design changes in the thermoelectrically-cooled quartz microbalance, which is used to monitor surface contamination in space simulation chambers, is described in terms of its extended temperature range, increased temperature control, mass sensitivity, and cooling power. The mass sensor uses 20 MHz quartz crystals having a sensitivity of 8.8 x 10 to the minus tenth power g/sq cm - Hz. The crystals are optically polished, metal plated, and overplated with magnesium fluoride to simulate an optical surface. The microbalance temperature circuitry is designed to readout and control surface temperature between 100 C and minus 59 C to plus or minus 0.5 C, and readout only temperature between minus 60 C and minus 199 C using auxiliary liquid nitrogen cooling. Data is included on the measurement of oil contamination of surfaces as a function of temperature in space simulation chambers.

D. McKeown↗

NASA NTRS1998

Pump, and earth-testable spacecraft capillary heat transport loop using augmentation pump and check valves

A spacecraft includes heat-generating payload equipment, and a heat transport system with a cold plate thermally coupled to the equipment and a capillary-wick evaporator, for evaporating coolant liquid to cool the equipment. The coolant vapor is coupled to a condenser and in a loop back to the evaporator. A heated coolant reservoir is coupled to the loop for pressure control. If the wick is not wetted, heat transfer will not begin or continue. A pair of check valves are coupled in the loop, and the heater is cycled for augmentation pumping of coolant to and from the reservoir. This augmentation pumping, in conjunction with the check valves, wets the wick. The wick liquid storage capacity allows the augmentation pump to provide continuous pulsed liquid flow to assure continuous vapor transport and a continuously operating heat transport system. The check valves are of the ball type to assure maximum reliability. However, any type of check valve can be used, including designs which are preloaded in the closed position. The check valve may use any ball or poppet material which resists corrosion. For optimum performance during testing on Earth, the ball or poppet would have neutral buoyancy or be configured in a closed position when the heat transport system is not operating. The ball may be porous to allow passage of coolant vapor.

Baker, David↗

NASA NTRS1983

Cooled grating infrared spectrometer for astronomical observations

A liquid helium-cooled infrared spectrometer for the 16 to 50 micron range is described. The instrument has six detectors, three each of Si:Sb and Ge:Ga and two diffraction gratings mounted back-to-back. Cold preoptics are used to match the spectrometer to the telescope. In its nominal configuration the system resolution is 0.03 micron from 16 to 30 microns and 0.07 micron from 28 to 50 microns. A cooled filter wheel is used to change order sorting filters. The gratings are driven by a steel band and gear train operating at 4 K. The detector outputs are amplified by a TIA, employing a matched pair of JFETs operating at 70 K inside the dewar. The external warm electronics include a gain stage for the TIA and dc-coupled gating circuit to remove charged-particle (cosmic-ray secondary)-induced noise spikes. The gating circuit reduces the overall system noise by a factor of two when the spectrometer is used on NASA's Kuiper Airborne Observatory. Sample spectra are presented and the deglitcher performance is illustrated.

Houck, J. R.↗

NASA NTRS2005

Interaction of Superconducting YBa2Cu(sub 3-x)Zn(sub x)O(sub 7-y) with MeV Radiation

When the high Tc superconductor Y-Ba-Cu-O is cooled with liquid nitrogen, the conduction holes form a macroscopic collective or entangled state. While collective effects have been observed with radiation energies up to 5 eV, no high-sensitivity experiments have previously been carried out to search for comparable effects with MeV radiation. Here an experiment using a pair of scintillation counters arranged to search for changes in the natural background of high energy radiation adjacent to a warm and cold Y-Ba-Cu-O superconductor is described. The experiment showed a shift toward higher pulse heights when the SC was cooled, with a 4 standard deviation excess of 9.12+/-2.28 events/ksec over the range of 0 to 18 MeV. The net difference spectrum shows a 5.5 standard deviation excess signal for the range of 3 to 6 MeV.

Lewis, R. A.↗

NASA NTRS1997

Film-Cooling Heat-Transfer Measurements Using Liquid Crystals

The following topics are discussed: (1) The Transient Liquid-Crystal Heat-Transfer Technique; (2) 2-D Film-Cooling Heat-Transfer on an AlliedSignal Vane; and (3) Effects of Tab Vortex Generators on Surface Heat Transfer. Downstream of a Jet in Crossflow.

Hippensteele, Steven A.↗

NASA NTRS2004

Cryogenic Electric Motor Tested

Technology for pollution-free "electric flight" is being evaluated in a number of NASA Glenn Research Center programs. One approach is to drive propulsive fans or propellers with electric motors powered by fuel cells running on hydrogen. For large transport aircraft, conventional electric motors are far too heavy to be feasible. However, since hydrogen fuel would almost surely be carried as liquid, a propulsive electric motor could be cooled to near liquid hydrogen temperature (-423 F) by using the fuel for cooling before it goes to the fuel cells. Motor windings could be either superconducting or high purity normal copper or aluminum. The electrical resistance of pure metals can drop to 1/100th or less of their room-temperature resistance at liquid hydrogen temperature. In either case, super or normal, much higher current density is possible in motor windings. This leads to more compact motors that are projected to produce 20 hp/lb or more in large sizes, in comparison to on the order of 2 hp/lb for large conventional motors. High power density is the major goal. To support cryogenic motor development, we have designed and built in-house a small motor (7-in. outside diameter) for operation in liquid nitrogen.

Brown, Gerald V.↗

NASA NTRS2023

Reliable Ignition of LOX Methane Propellants in Thermal Vacuum Environment

The goal of this project is to demonstrate reliable ignition of liquid oxygen-liquid methane at thermal vacuum conditions using a coil-on-plug (COP) sparking exciter. Testing will be performed using EP’s Frost-Mint cryogenic propellant test stand, using an engine updated based on data collected from previous engine testing at Plum Brook Station, to determine conditions under which the cryogenic propellants will consistently and reliably ignite. In FY22 the project successfully completed the following milestones. The cryogenic test stand Frost-Mint was upgraded to include an integrated vacuum tube and liquid nitrogen cooling system enabling cold vacuum ignition testing. The Integrated GN2/LN2 Ultra-Low-temperature Enclosure (IGLUE), a custom-built close-coupled heater exchanger shroud was designed, fabricated, tested and integrated into the test stand. The vacuum tube and IGLUE enabled the thruster body and propellants to be conditioned to temperatures and pressures desired. This work recreated the no-light conditions experienced during vehicle-level thermal vacuum testing and obtained thruster performance data and ignition imagery.

liquid oxygen↗

DOE OSTI2024

Extreme Metastability of Diamond and its Transformation to the BC8 Post-Diamond Phase of Carbon

Diamond possesses exceptional physical properties due to its remarkably strong carbon–carbon bonding, leading to significant resilience to structural transformations at very high pressures and temperatures. Despite several experimental attempts, synthesis and recovery of the theoretically predicted post-diamond BC8 phase remains elusive. Through quantum-accurate multimillion atom molecular dynamics (MD) simulations, we have uncovered the extreme metastability of diamond at very high pressures, significantly exceeding its range of thermodynamic stability. We predict the post-diamond BC8 phase to be experimentally accessible only within a narrow high pressure–temperature region of the carbon phase diagram. The diamond to BC8 transformation proceeds through premelting followed by BC8 nucleation and growth in the metastable carbon liquid. Here we propose a double-shock compression pathway for BC8 synthesis, which is currently being explored in experiments at the National Ignition Facility.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2026

FGMS-poster

Idaho National Laboratory (INL) performs post irradiation examination (PIE) of tri-structural isotropic (TRISO)-coated particle fuel to help qualify it for high temperature gas cooled reactors. TRISO fuel compacts are re-irradiated in the Neutron Radiography Reactor (NRAD) to generate the short lived fission products needed for fission product release testing. The Fuel Accident Condition Simulator (FACS) furnace and newly added Screen Neutron Irradiated Fuel for Failure (SNIFF) furnace heat the compacts in helium to temperatures of up to 2,000°C, prompting fission product release—predominantly gaseous xenon and krypton isotopes and condensable products such as cesium—from failed particles. These released isotopes are transported to a fission gas monitoring system (FGMS 1 or FGMS 3), where they accumulate in cryogenic cold traps and are quantified using high-purity germanium (HPGe) detectors. The addition of SNIFF and FGMS 3 increases throughput by enabling simultaneous testing of multiple compacts. Furthermore, automated INL developed software provides continuous, near-real time monitoring of fission product inventories and manages the liquid nitrogen cooling of the traps. These system enhancements improve the efficiency, data quality, and testing capacity of TRISO fuel performance evaluations.

07 - ISOTOPES AND RADIATION SOURCES↗

DOE OSTI2020

Design and Fabrication of the Mu2e Cryogenic Distribution System

The muon-to-electron conversion (Mu2e) experiment at Fermilab will be used to search for the charged lepton flavor-violating conversion of muons to electrons in the field of an atomic nucleus. The Mu2e experiment is currently in the design and construction stage and is expected to begin operations in 2022. The Mu2e experiment uses four large superconducting solenoid magnets including a Production Solenoid (PS), an Upstream and Downstream Transport Solenoid (TSu and TSd) and a Detector Solenoid (DS). This paper will focus on the cryogenic distribution system for these four solenoid magnets. Liquid helium will be supplied from two re-purposed Tevatron satellite refrigerators. A large cryogenic distribution box (DB) is located in the Mu2e building to distribute the required cryogens to each of the four solenoid magnets. Each solenoid magnet will have a dedicated transfer line and cryogenic feed box (FB). The solenoid magnets each require two liquid helium circuits and two liquid nitrogen circuits. The most unique feature about this cryogenic system is that the assemblies for the start of the superconducting portion of the power leads are mounted in feed boxes that are in the range of 23 m to 31 m away from the solenoid magnets. The cryogenic feed boxes are located remotely to provide protection from radiation damage and high magnetic fields. The power leads are NbTi superconducting cable stabilized with high conductivity aluminum. The 6061-T6 aluminum grade was selected for the transfer line piping so that the piping would thermally contract at the same rate as the power lead. A major concern for this transfer line is that a small helium leak could create an electric discharge arc due to the Paschen effect. This paper includes a description of the design features and testing done to ensure that the power leads are protected from the Paschen effect while still being adequately cooled to liquid helium temperatures.

43 PARTICLE ACCELERATORS↗

DOE OSTI2023

Thermal Hydraulic Experimental Test Article - Fiscal Year 2023 (Final Report)

The Thermal Hydraulic Experimental Test Article (THETA) is a facility that is used to develop sodium components and instrumentation as well as acquire experimental data for validation of reactor thermal hydraulic and safety analysis codes. The facility simulates nominal conditions as well as protected/unprotected loss of flow accidents in a sodium-cooled fast reactor (SFR). High fidelity distributed temperature profiles of the developed flow field may be acquired with Rayleigh backscatter based optical fiber temperature sensors. The facility was designed in partnership with systems code experts to tailor the experiment to ensure the most relevant and highest quality data for code validation. THETA is comprised of a traditional primary coolant and secondary coolant system. The primary system is submerged in the pool of sodium and consists of a pump, electrically heated core, intermediate heat exchanger, and connected piping and thermal barriers (redan). The secondary system, located outside of the sodium pool, consists of a pump, sodium to air heat exchanger, and connected piping and valves. To date a test matrix has been completed utilizing the primary system of THETA. These tests, along with computational fluid dynamics and systems code models, determined the heat transfer across the core barrel and intermediate heat exchanger outlet was too great to effectively represent scaled thermal hydraulic phenomena of a liquid metal cooled reactor. Therefore, a significant effort was made to remove the primary system from the METL 28” test vessel #4 and clean the residual sodium from the primary system to facilitate upgrades. Thermal insulation was then incorporated in the core barrel and intermediate heat exchanger outlets. The primary system was then replaced, and a series of tests were performed to assess the performance of the thermal insulation. With primary system testing and upgrades complete, the secondary system could then be brought online. The tube side of the shell-and-tube intermediate heat exchanger was installed onto the primary system flange to begin installing the secondary system. The support structure for the secondary system was then erected on the METL mezzanine alongside the THETA primary system to facilitate installation of the secondary system components (sodium-to-air heat exchanger, flowmeter and pump). The piping and expansion tank were welded into the secondary system. Non-destructive examination of the secondary system welds was completed in order to satisfy ASME B31.3 pipe code for class M process fluids. The heating system and insulation were then added to prepare the system to be filled with sodium. The ancillary electrical equipment was installed which included the pump control box, blower VFD, pipe heater control system, etc. The secondary system will be filled, and a test matrix will be completed in early FY2024.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2024

Report on Initial Sodium Testing on the Thermal Hydraulic Experimental Test Article (THETA) (Fiscal Year 2024 Final Report)

The Thermal Hydraulic Experimental Test Article (THETA) is a facility that is used to develop sodium components and instrumentation as well as to acquire experimental data for validation of reactor thermal hydraulic and safety analysis codes. The facility simulates nominal thermal hydraulic conditions as well as protected/unprotected loss of flow accidents in a sodium-cooled fast reactor (SFR). High fidelity distributed temperature profiles of the developed flow field may be acquired with Rayleigh backscatter based optical fiber temperature sensors. The facility was designed in partnership with systems code experts to tailor the experiment to ensure the most relevant and highest quality data for code validation. THETA is comprised of a traditional primary coolant and secondary coolant system. The primary system is submerged in the pool of sodium and consists of a pump, electrically heated core, intermediate heat exchanger, and connected piping and thermal barriers (redan). The secondary system, located outside of the sodium pool, consists of a pump, sodium to air heat exchanger, and connected piping and valves. In fiscal year 2023, thermal stratification tests were completed with the primary system online, while the secondary system was being constructed [1]. These tests had shown that the core barrel and intermediate heat exchanger (IHX) outlet required increased thermal insulation. The THETA primary system was removed from METL, cleaned, thermal insulators installed, and then inserted into METL Test Vessel 4. At the time of this writing the THETA primary and secondary system are operational. During this fiscal year 100+ hours of testing was completed to characterize thermal hydraulic phenomena associated with steady state and transient conditions in a pool type liquid metal cooled reactor. A majority of the testing campaign was completed to satisfy the experimental data acquisition requirements for the GAIN Voucher with Oklo, CRADA 2021-21121. THETA is still operational at the time of this publication and future testing is planned for fiscal year 2025. Work is underway to publish existing and future data to an online database to facilitate collaboration with SFR engineers looking to validate their systems code or computational fluid dynamics models.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1999

Hydrazine Detection with a Tunable Diode Laser Spectrometer

Several instruments have been developed to measure low concentrations of hydrazine but none completely meet the sensitivity requirements while satisfying additional criteria such as quick response, stable calibration, interference free operation, online operation, reasonable cost, etc. A brief review is presented of the current technology including the electrochemical cell, the ion mobility spectrometer, the mass spectrometer, and the gas chromatograph. A review of the advantages and disadvantages of these instruments are presented here. The review also includes commercially unavailable technology such as the electronic nose and the Tunable Diode Laser (TDL) IR Spectrometer. It was found that the TDL could meet the majority of these criteria including fast response, minimum maintenance, portability, and reasonable cost. An experiment was conducted to demonstrate the feasibility of such a system using an existing (non-portable) instrument. A lead-salt tunable diode laser, cooled to 85 degrees Kelvin was used to record direct absorption and second-derivative spectra of Hydrazine at several pressures to study the sensitivity to low levels of Hydrazine. Spectra of NH3 and CO2 were used for wavelength identification of the scanned region. With a pathlength of 80 m, detection sensitivities of about 1 ppb were achieved for hydrazine in dry nitrogen at a cell pressure of 100 mbar. For spectroscopic detection of Hydrazine, spectral regions including strong Ammonia or Carbon Dioxide lines must be avoided. Strong Hydrazine absorption features were identified at 940/cm showing minimal contribution from Ammonia interferences as suitable candidates for Hydrazine gas detection. For the studies reported here, the particular laser diode could only cover the narrow regions near 962/cm and 965/cm where strong Ammonia interferences were expected. However, the high resolution (0.001/cm) of the TDL spectrometer allowed individual lines of Hydrazine to be identified away from interferences from either Ammonia or Carbon Dioxide, especially at lower pressures. A Hydrazine line was identified at 961.75/cm which was free from Ammonia absorption and would be suitable to monitor hydrazine levels. This paper also shows data on the degradation of the detectivity of Hydrazine with increasing pressure. Several design options for a portable unit are presented, including designs with near IR and Quantum Cascade laser components which do not require liquid nitrogen cooling.

Houseman, John↗