Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “heating”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 685 records · Page 38
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Generalizability of heat-related health risk associations observed in a large healthcare claims database of patients with commercial health insurance

Extreme ambient heat is unambiguously associated with higher risk of illness and death. The Optum Labs Data Warehouse (OLDW), a database of medical claims from US-based patients with commercial or Medicare Advantage health insurance, has been used to quantify heat-related health impacts. Whether results for the insured sub-population are generalizable to the broader population has to our knowledge not been documented. We sought to address this question, for the US population in California from 2012 to 2019. We examined changes in daily rates of emergency department (ED) encounters and in-patient hospitalization encounters for all-causes, heat-related outcomes, renal disease, mental/behavioral disorders, cardiovascular disease, and respiratory disease. OLDW was the source for health data for insured individuals in California, and health data for the broader population were gathered from the California Department of Health Care Access and Information (HCAI). We defined extreme heat exposure as any day in a group of 2 or more days with maximum temperatures exceeding the county-specific 97.5 th percentile and used a space-time-stratified case–crossover design to assess and compare the impacts of heat on health. Average incidence rates of medical encounters differed by dataset. However, rate ratios for ED encounters were similar across datasets for all causes (ratio of incidence rate ratios (rIRR) = 0.989; 95% confidence interval (CI) = 0.973, 1.011), heat-related causes (rIRR = 1.080; 95% CI = 0.999, 1.168), renal disease (rIRR = 0.963; 95% CI = 0.718, 1.292), and mental health disorders (rIRR = 1.098; 95% CI = 1.004, 1.201). Rate ratios for inpatient encounters were also similar. This work presents evidence that OLDW can continue to be a resource for estimating the health impacts of extreme heat.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Preliminary Experiences with the Rexon UL-320-FDR: An Automated Thermoluminescent Dosimeter Reader with Removable Contact Heating Planchets and an Infrared Temperature Feedback System

The Rexon UL-320 FDR is a novel resistive-heating thermoluminescent dosimeter reader with a unique temperature measurement system and an automated dosimeter processing mechanism. The removable contact heating planchets have black-body adhesives on the back for capturing temperature information with infrared sensors. A heating cycle feedback loop ensures accurate, precise, and reproducible heating sequences. Heating rates between 0.8 and 40°C s -1 for up to 1,000 s are possible. Photomultiplier tube sensitivity and drift, dark current counts, and planchet glow were measured experimentally. Additionally, 25 LiF:Mg,Ti dosimeters were calibrated to demonstrate reader performance. Sensitivity was optimized at 1,200 V, which produced the highest reference light count to dark current count ratio while extending photomultiplier tube life. Dark current counts measured with typical time-temperature profiles for LiF:Mg,Ti were below 10 counts per channel but increased by up to 2.5% for more extreme heating cycles. Reader sensitivity drifts of up to 10% were observed during extended automated operations with typical time-temperature profiles. Total counts resulting from planchet glow decreased with faster heating rates. Calibrations performed with LiF:Mg,Ti dosimeters yielded results comparable to more established reader designs. Spikes were observed in ~3% of the glow curves from planchet dust and oil burning off at elevated temperatures. The use of N 2 gas and sensitivity drift corrections are recommended to improve dosimetry performance for the UL-320 FDR reader.

61 RADIATION PROTECTION AND DOSIMETRY↗
DOE OSTI2020

Active Temporal Control of Radiative Heat Transfer with Graphene Nanodisks

The ability to dynamically control the radiative transfer of heat at the nanoscale holds the key to the development of a diverse number of technologies, ranging from nanoscale thermal-management systems to improved thermophotovoltaic devices. Recently, graphene has emerged as an ideal material to achieve this goal, since it can be electrically doped to support surface plasmons, collective oscillations of the conduction electrons. These resonances produce large and spectrally narrow optical cross sections, which dictate the emission and absorption properties of the graphene nanostructure and, thus, the heat that it radiatively exchanges with other objects and the environment. For attainable levels of doping, the plasmons supported by graphene nanostructures naturally lie in the midinfrared part of the spectrum, which is the most relevant wavelength range for radiative heat transfer under realistic temperatures. Furthermore, these resonances are actively tunable, thus providing full dynamic control over the heat transfer. Motivated by this great potential, we present a comprehensive analysis of the temporal evolution of the radiative heat transfer between arrangements of graphene nanodisks, showing that it is possible to exploit the tunability of these structures to obtain actively controlled heat transfer scenarios not possible with conventional passive nanostructures. We report the results of this work provide a framework for achieving fully dynamical control over nanoscale radiative heat transfer and thus provide fundamental insights into this process.

36 MATERIALS SCIENCE↗
DOE OSTI2022

A Method to Identify the Heat Flux From Photons and Neutrals at the Divertor Target

The Surface Eroding Thermocouple (SETC) is a diagnostic designed for fast surface heat flux measurement and has been successfully applied in DIII-D to investigate divertor detachment. A novel method has been developed of using a combination of surface-facing and recessed SETCs to distinguish between the heat flux from charged particles, and that from neutrals and radiative heating. Furthermore, this technique suggests that at least 20% of the total incident heat flux is attributable to the latter sources not trapped in the magnetic field in a fully detached open divertor condition. It not only indicates the non-charged particle heating significantly contributes to the total surface heat flux in detached divertor conditions, but also demonstrates the feasibility of using two operational modes of SETCs to distinguish between the two surface heating mechanisms.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Experimental Analysis of Salt Hydrate Latent Heat Thermal Energy Storage System With Porous Aluminum Fabric and Salt Hydrate as Phase Change Material With Enhanced Stability and Supercooling

Phase change materials (PCMs), especially salt hydrates possess high volumetric energy storage capacity in their transition temperature range. These materials are used in applications where it is necessary to store thermal energy due to temporary load shift between demand and availability. Thus, possible applications are HVAC, recovery of waste heat, and defense thermal management. Despite salt hydrates potential, the practical feasibility of latent heat storage with salt hydrates is limited due to low power rating, supercooling, phase segregation, and long-term stability. Its low power rating and long-term stability limits its application in most applications. This work experimentally validates the stability and thermal performance of a compact heat exchanger charged with salt hydrate during melting and freezing. The compact heat exchanger was designed with fins on both the heat transfer fluid (HTF) and salt hydrate PCM side. The thermal performance of the latent heat thermal energy storage system (LHTESS) was evaluated for various operating conditions. The results show that LHTESS could achieve an average heat transfer coefficient of 124 and 87 W/(m2 K) during melting and solidification, respectively. The stability of the system in suppressing supercooling was validated over 800 cycles with nucleating agent and active homogenous nucleation techniques. The supercooling was reduced to 3 °C with zinc hydroxyl nitrate as nucleating agent and less than 1 °C with the active homogenous nucleation technique. The LHTESS showed less than 6% degradation in energy storage capacity over 800 cycles.

42 ENGINEERING↗
DOE OSTI2021

Heat Exchanger Design Optimization for Mitigation of Diesel Engine Exhaust Fouling

Abstract The design optimization of a diesel exhaust-coupled heat and mass exchanger that drives a 2.71 kW cooling capacity absorption heat pump is presented in this study. Fouling layer thermal resistance and pressure drops from single-tube experiments are used to develop a thermodynamic, heat transfer, and pressure drop model for the exhaust-coupled desorber. A parametric study is performed to select a desorber design that meets system performance while minimizing footprint. Experimental heat duties and pressure drops are within 10% and 3%, respectively, of the model predictions. Thus, large data sets from single-tube experiments with representative geometries are successful in accounting for fouling effects at the component level. Desorber design optimization based on this approach ensures continued heat pump performance after fouling. This study, along with the single-tube experiments, presents a systematic approach to design exhaust-coupled heat exchangers while considering the effects of fouling. These results are applicable for a wide range of waste-heat recovery applications, and this method can be extended to different geometries and operating conditions.

Energy & Fuels↗
DOE OSTI2023

Experimental and Computational Heat Transfer Study of sCO 2 Single-Jet Impingement

This study experimentally and computationally investigates the heat transfer capability of supercritical carbon dioxide (sCO 2 ) single jet impingement. The evaluated jet Reynolds number range is between 80,000 and 600,000, with a nondimensional jet-to-target surface spacing of 2.8. CO 2 -impinging jet stagnation conditions were maintained at approximately 200 bar and a temperature of ∼400 °C for most experiments. The goal is to understand how changes in the aforementioned parameters influence heat transfer between the working fluid and the heated surface. Additionally, due to the elevated Reynolds numbers and difference in thermodynamic properties between air and CO 2 , air-derived impingement correlations may not be appropriate for CO 2 impingement; these correlations will be evaluated against experimental sCO 2 impingement data. At the time of this study, no sCO 2 impingement data was available relevant to sCO 2 power cycles. The target surface is a 1.5-in. diameter copper block centered on the 3 mm jet orifice. A mica heating element bolted to the bottom of the copper block provides a uniform heat flux. Thermocouples embedded in the copper block are used to determine the surface temperature. Nusselt numbers obtained from experimental sCO 2 test data are compared to area-averaged Nusselt numbers from air-derived correlations. The comparisons showed that air correlations drastically underpredict the heat transfer when sCO 2 is used as the working fluid. A modified sCO 2 correlation using experimental data at discussed conditions is derived based on an existing air correlation. A CFD study is also performed to further investigate sCO 2 heat transfer characteristics, and assess the numerical model applicability to this problem type.

42 ENGINEERING↗
DOE OSTI2026

Snow-eater heat waves of the western United States

Abrupt snowmelt, triggered by rain-on-snow events or "snow-eater heat waves," can cause flooding, initiate or accelerate snow drought, and affect water availability. However, the characteristics (e.g., area, duration, and frequency), impacts, and trends of snow-eater heat waves have received little attention. To address this gap, we developed a method to identify snow-eater heat waves and estimate their melt potential using 20th Century Reanalysis version 3 air temperature data, the TempestExtremes algorithm, and an operational snowmelt model (SNOW-17) across 1850-2015. Melt season snow-eater heat waves typically last 3 to 5 days, with three to five events, doubling snowmelt rates. Seven of 11 spring superfloods are shown to coincide with snow-eater heat waves. Since the 1850s, snow-eater heat waves have increased in area and frequency, decreased in duration, and shifted earlier in the melt season. Incorporating snow-eater heat-wave impacts into SNOW-17 enhances extreme melt estimates, improving water management support tools.

Rhoades, Alan M↗
DOE OSTI2025

sup3ruhi (Super Resolution for Renewable Resource Data and Urban Heat Islands) [SWR-25-05]

Urban heat is a growing concern, particularly in dense metropolitan areas where high temperatures increase the risk of heat-related illness and drive energy expenses for cooling. Estimating the effects of urban heat remains a challenge due to limitations in describing the built environment, computational constraints, and the need for high-resolution data. This software presents open-source, computationally efficient machine learning methods that enhance the accuracy of urban temperature estimates compared to historical reanalysis data. Models trained using this software have been applied to urban microclimates in Los Angeles and Seattle showing greater accuracy and less bias when compared to low-resolution reanalysis datasets like ERA5 and even when compared to high-resolution mesoscale numerical weather models like WRF with an urban canopy model. Initial findings highlight how machine learning can support urban heat resilience planning by enabling improved assessments of local heat islands, mitigation strategies, and their energy implications. This software is an extension of (sup3r). This software supports the following publication: Buster, Grant, et al. Tackling Extreme Urban Heat: A Machine Learning Approach to Assess the Impacts of Climate Change and the Efficacy of Climate Adaptation Strategies in Urban Microclimates. arXiv:2411.05952, arXiv, 8 Nov. 2024. arXiv.org, https://doi.org/10.48550/arXiv.2411.05952. And has related public data records available at: Buster, Grant, Cox, Jordan, Benton, Brandon, and King, Ryan. Super-Resolution for Renewable Resource Data and Urban Heat Islands (Sup3rUHI). United States: N.p., 16 Oct, 2024. Web. https://data.openei.org/submissions/6220.

Buster, Grant [National Renewable Energy Laborator↗
DOE OSTI2020

Getting things done onsite: Heat Source production never ramps down

The COVID-19 pandemic has changed many norms in the world and at LANL. During the rapid transition of sending many to work from home in March, some programs were deemed mission critical, with the expectation to continue driving their missions forward. One of those essential programs is Heat Source Technologies, a group within the Actinide Material Power & Processing (AMPP) Division at TA-55. Within the Associate Laboratory Directorate of Weapons Production (ALDWP), the group responsible for the Pu-238 heat sources continued their work nearly uninterrupted as many others made the mandatory transition to work remotely. This group, known as AMPP-1, Heat Source Technologies, works on the production line producing heat sources from Plutonium (Pu)-238, which is an essential mission for National Security. This group is comprised of nearly 90 employees and operates out of the TA-55 Plutonium Facility (PF-4 and PF-5) producing heat sources. Heat source production includes the operations that purify, process, and weld Pu-238 oxide into encapsulated heat sources that are essential for space and defense missions.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗
DOE OSTI2020

3D CFD Model Validation Using Benchmark Data of 1/16th Scaled VHTR Upper Plenum and Development of Wall Heat-Transfer Correlation For Laminar Flow

With support from the U.S. Department of Energy-Office of Nuclear Energy’s (DOE-NE’s) Nuclear Energy Advanced Modeling and Simulation (NEAMS) program, an effort has been pursued to support high-temperature gas-cooled reactor (HTGR) technology development and its modeling and simulation needs. There is a particular need for advanced modeling and simulation tools to predict thermal-fluid behavior in the nuclear reactor primary system, especially in the core and the lower and upper plena, during safety-related transients. In this report, two main such activities are presented relevant to the HTGRs: (1) three-dimensional (3D) computational fluid dynamics (CFD) validation using benchmark data from the upper plenum of Texas A&M University’s 1/16th scaled very-high-temperature gas-cooled reactor (VHTR), and (2) development of wall heat-transfer correlation for laminar flow in a wall-heated pipe. The CFD tool validation exercises can be helpful to choose the models and CFD tools to simulate and design specific components of the HTRGs such as upper plenum where jet mixing is a complex phenomenon. In a loss of forced circulation event, the laminar flow can be observed during the development of natural circulation flow. This work includes the development and validation of heat transfer correlations for laminar flow using the Nek5000 CFD code due to limited available experimental data for laminar flow conditions to guide low-order models (1D). In this report, the flow characteristics of a single isothermal jet discharging into the upper plenum was investigated using the Nek5000 Large-Eddy Simulation (LES) CFD tool. Several numerical simulations were performed for various jet-discharged Reynolds numbers ranging from 3,413 to 12,819. A grid-independent study was performed. The numerical results of mean velocity, root-mean-square fluctuating velocity, and Reynolds stress were compared against the benchmark data. Good agreement was obtained between simulated and measured data for axial mean velocities, except near the upper plenum hemisphere. The maximum predicted errors for axial mean velocities at various normalized coolant channel diameter heights of 1, 5, and 10 are 1.56%, 1.88%, and 3.82%, respectively. In addition, the predicted root-mean-square fluctuating velocity and Reynolds stress are qualitatively in agreement with the experimental data. The Nek5000 code was used to develop wall-heat transfer correlation for laminar flow in a cylindrical tube. Several simulations were performed for various Reynolds flow and wall-heat fluxes. A new heat transfer correlation was developed using data from Nek5000 simulation results and regression functions in Matlab. The developed heat transfer correlation is valid for various Reynolds flows from 200 to 2000. The predicted R² value for model fit was 0.875, which ensures that 87.5% of the model data lies on the Nek5000 data. Moreover, a machine learning (ML) tool was used to train and test the Nek5000 data. A good fit of the ML-based model was observed with the test data.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2020

Quantitative form and fit of N95 filtering facepiece respirators are retained after dry and humid heat treatments for coronavirus deactivation

Re-use of filtering facepiece respirators (FFRs, commonly referred to as N95s) normally meant for single use only is becoming common in healthcare facilities due to shortages caused by the COVID19 pandemic. Here we report that mouse hepatitis virus (MHV) initially seeded on FFR filter material is inactivated (6 log reduction as measured by 50% tissue culture infective dose (TCID50)) after dry heating at 75 °C for 30 minutes. We also find that the quantitative fit of FFRs after heat treatment at this temperature, under dry conditions or at 90% relative humidity, is not affected by single or ten heating cycles. Previous studies have reported that the filtration efficiency of FFR filters is not negatively impacted by these heating conditions. These results suggest that thermal inactivation of coronaviruses is a potentially rapid and widely deployable method to re-use N95 FFRs in emergency situations where reusing FFRs is a necessity and broad-spectrum sterilization is unavailable. However, we also found that a heat source that emits radiation (e.g., an exposed heating element) results in rapid qualitative degradation of the FFR. Finally, we discuss differences in the results reported here and other recent studies investing heat as a means to recycle FFRs and suggest that overall wear time and donning/doffing cycles are important factors that need to be considered.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Capillary-driven Condensation for Heat Transfer Enhancement in Steam Power Plants

A novel condensation method was developed to enhance the efficiency of steam power plants. The method consists of a hierarchical structure on the surface of condenser tubes consisting of a wicking structure overlaid with a porous hydrophobic membrane. The project is divided into two main efforts. First, a structure with highly defined geometry was made utilizing microfabrication on silicon. This structure helped us elucidate the physics of steam condensation at the surface, more easily model the heat transfer coefficient, and demonstrate the first proof-of-concept for our proposed condensation approach. The structures on silicon achieved a heat transfer coefficient ~ 240% higher than the theoretical filmwise value at the same operating condition. Second, the method is explored for scalability by fabricating surfaces with industrial class materials followed by heat transfer measurements on flat surfaces. An HTC enhancement of 50% over the experimental filmwise value was achieved on hierarchical copper surfaces made of commercially available copper foams and meshes, showing the potential of achieving heat transfer enhancement using low cost and scalable materials. Scalable fabrication of the hydrophobic membrane and the porous copper wick were also investigated. Our heat and mass transfer model predicts a > 5x heat transfer enhancement on a scalable version of capillary driven condenser made of membrane covered porous copper. The results demonstrate the promise of capillary-driven condensation surfaces for heat transfer applications.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2021

Enhancing Steam-Side Heat Transfer via Microdroplet Ejection using Inorganic Coatings

During condensation of water on a superhydrophobic nanostructured surfaces, droplets coalesce and jump (droplet ejection) due to the release of excess surface energy. Meticulously designed nanostructured surfaces or coatings capable of droplet ejection can enhance heat transfer performance by easy removal of droplets during condensation. In the present work, the capabilities of the Nelumbo droplet ejection coatings technology currently used in commercial heat exchangers are explored and optimized for materials and conditions relevant to steam condensers. Specifically, this includes (1) adapting and optimizing the procedures and chemistries to deposit droplet ejecting coatings on materials used in the steam condenser, (2) testing of the heat transfer, durability, and fouling of the fabricated coatings under a variety of steam condenser relevant conditions, and (3) modeling of the impact of droplet dynamics and interfacial properties on heat transfer in steam condensers. We experimentally demonstrated that at low supersaturation conditions (S~1.02), developed superhydrophobic nanostructured surface gives a 40% higher peak heat transfer flux and a 17% higher peak overall heat transfer coefficient (U) with droplet ejection mechanism compared to the dropwise condensation mechanism on the same nanostructured surface. Though the experimentally observed droplet ejection mechanism was short-lived (~3 min) due to the limitation of the chiller to maintain a constant supersaturation condition in fabricated steam condenser. And large variations in water inlet temperature (+ to - 2 degrees C) caused flooding of nanostructure (Wenzel state) at higher supersaturation (S > or = 1.12). This is an important finding because typical supersaturation levels in field operation are over 1.8 and as such, either the flooding potential for these materials should be improved or operation at lower supersaturation may be required to maximize heat transfer efficiency. If supersaturation conditions can be maintained reliably in the steam condenser in addition to droplet ejection mechanism during condensation, this could provide a potential 2% reduction in water flow rate which equates to a savings of over 3900 gallons of water per minute for a 500 MW steam turbine and over $0.3MM savings annually given a 0.02 cent marginal water withdrawal cost. It is also worth noting that these savings are based on improvement of droplet ejection coatings over coatings capable of performing consistent dropwise mechanism in in-field surface condensers. Savings due to the droplet ejections coatings when compared to bare substrates could be much higher. Additionally, the present work provides the importance of steam condenser operating conditions and insights into the challenges in modeling the condensing droplet dynamics on surfaces.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2022

A Process with Decoupled Absorber Kinetics and Solvent Regeneration through Membrane Dewatering and In-Column Heat Transfer (Final Report)

This report summarizes the work conducted on project DE-FE0031604 where University of Kentucky Center for Applied Energy (UK CAER) has validated its intensified CO 2 capture process through substantial enhancements to the kinetics of the absorption process and energy reductions by absorber temperature profile modification, dewatering and heat integration technologies for achieving significant capital and operating cost reductions. To address DOE’s objective of improving post-combustion CO 2 capture technology and reducing associated cost, UK CAER employed an intensified process which combined three key aspects targeted at overcoming inherent limitations or barriers in the conventional CO 2 capture and desorption process. The process designed to be independent of the type of solvent used, included (1) the use of 3-D printed two-channel structured packing material to control the temperature profile and increase the CO 2 absorption rate in the absorber, (2) a zeolite membrane dewatering unit for dewatering of the carbon-rich solvent to decouple solvent concentration needs for CO 2 absorption and desorption, and (3) a rich-split feed with two-phase flow heat transfer prior to the stripper that provided a secondary point of vapor generation to provide energy savings in steam extraction and solvent regeneration. The project was executed over two budget periods. This involved testing of individual process components which included the advanced heat transfer packing and the dewatering membrane on UK CAER’s 30 liter per minute (L/min) CO 2 (3” Column) capture bench unit with simulated flue gas in the first budget period. Subsequent scaled-up testing of these components together with the split-feed configuration were also tested in UK CAER’s 0.1 MWth CO 2 capture unit with coal-derived flue gas in the second-budget period. Long term studies were done during this period to assess process and solvent performance over extended duration. Project partners Lawrence Livermore National Laboratory (LLNL) and Media & Process Technology (MPT) led the development efforts for the advanced packing material and dewatering membrane respectively. Data from the long term testing was used as input for an environmental, health and safety (EH&S) assessment for the process and scaled technology performed by ALL4 LLC. Trimeric Corporation also completed a techno-economic analysis (TEA) for the UK CAER technology which was compared to the DOE reference Case B12B. Tests on the 3” column capture unit showed that the advanced heat transfer packing could be used to lower the bulge temperature in the absorber, and this was also proven in the scaled testing in the 0.1 MWth CO 2 capture unit. The bulge temperature could be lowered by >10 °C, changing the temperature profile in the absorber, and showed potential to enhance absorption with the ability to tailor the profile to provide conditions suitable for a solvent’s properties and kinetics. Conditions for short term evaluation of a 19” zeolite dewatering membrane on the 3” column capture unit yielded desirable fluxes and sustained rejection rates of >80%. However, for the scaled testing of six membrane modules consisting of 21 parts of 31-inch-long membrane tubes in each bundle (surface area 0.3 m 2 ), over a more extended duration, similar rejection rates could not be achieved. With the split-feed of the rich stream to the stripper, improved heat recovery minimized waste heat exiting the top of the stripper. The stripper exhaust temperatures could be reduced by >10 °C; reducing the amount of water vaporization contributed to lowering the regeneration energy by ~ 15%. The energy benefit could be sustained from the long term monitoring of the solvent performance. The solvent properties were not significantly impacted over the long-term operations. The benefits of the UK CAER process demonstrated experimentally were mostly validated from the TEA comparing a commercial scale application of the technology to DOE reference Case B12B. The cost of CO 2 capture for the UK CAER technology was estimated to be ~$34.97/tonne of CO 2 captured; a reduction of 23% compared to Case B12B. The increase in cost of electricity was also shown to be 16% lower than that of Case B12B. The total parasitic demand was also shown to be 11% lower. The key drivers for the benefits are a result of the process intensification approaches employed in the UK CAER technology for enhanced solvent performance, effective heat recovery and improved energy performance. The EH&S assessment did not find any major environmental concerns or barriers to the full scale implementation of the technology.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2022

Predictive Tools for Customizing Heat Treatment of Additively Manufactured Aerospace Components

Laser-bed powder fusion (LBPF) additive manufacturing is increasingly being used to produce components of complex geometries using the Ni-base superalloy Inconel 718. The composition and the microstructure of the alloy are currently well optimized for wrought components made using conventional manufacturing processes such as rolling, forging, extrusion, etc. The attractive mechanical properties of the alloy result from the underlying austenitic matrix with fine equiaxed grains, and a high density and uniform distribution of the precipitation hardening phase, γ". Heat treatment steps such as homogenization, solutioning and aging are well documented for the wrought alloy. However, when the same wrought alloy compositions are used for the additive manufacturing (AM) processes, the asprocessed microstructure is significantly different, because of the different thermal history associated with LBPF, including rapid solidification and multiple temperature excursions that lead to multiple re-melting and reheating in the solid state. Rapid solidification introduces potential non-equilibrium effects at the moving solid-liquid interfaces that impact the extent of solute segregation, as well as the morphology of the dendritic grains that form. In order to recover the target mechanical properties, AM components have to undergo post-process heat treatments. However, such heat treatments have to be custom designed for the AM process and the component geometry because of the expected vast differences in the microstructure at various locations of a component with complex geometry. The homogenization and precipitation steps should be optimized for the component so that target mechanical properties can be obtained throughout the part. The objective of this research is to utilize High Performance Computing in phase field simulations of microstructure evolution during post-processing of AM components. The physics-based modeling will be beneficial in reducing the experimental effort required for heat treatment process selection, optimization, and certification, thus leading to a significant reduction in energy consumption for AM and post-processing heat treatment. The optimization study will help identify heat treatments steps that are critical for development of a final desired microstructure with the minimum energy input. This combined with shortening of the production cycle (time-to-market) by reducing the number of failed parts (property targets), and reduction in the number of iterations for process optimization, will enable 30-40% savings in the energy costs. Phase field simulations of the degree of homogenization and the effect of local matrix composition on the nucleation and growth of competing precipitating phases were performed using the Microstructure Evolution Using Massively Parallel Phase Field Simulations code developed in-house at the Oak Ridge National Laboratory. The simulations were able to successfully capture the kinetics of nucleation and growth, and morphologies of various precipitating phases as a function of local matrix compositions and composition gradients characteristic of local microstructures arising from location-dependent variations in the thermal conditions. Future work will involve extending the simulations to a length scale consisting of multiple dendrites, so that the effect of homogenization on the coarsening of the dendrites can be simulated and used as an additional input to the optimization of the heat treatment process.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Coupled Decay Heat and Thermal Hydraulic Capability for Loss-of-Coolant Accident Simulations

As the nuclear energy industry considers ways to achieve improved economics in the current fleet of light-water reactors (LWRs), one possible approach is to operate each cycle for longer durations. This causes a greater portion of the fuel to be burned and reduces the frequency of outages, which ultimately reduces the cost to operate the reactor. However, this also leads to higher burnup fuels than has traditionally been allowed in these reactors. Thus, there are concerns about integrity of high-burnup (HBu) fuel, especially during accident conditions such as loss-of-coolant accidents (LOCAs), as shown by Capps et al.. To investigate these concerns, advanced modeling and simulation capabilities are being leveraged to determine the susceptibility of HBu fuel to fuel fragmentation, relocation, and dispersion (FFRD). Improvements have previously been made to fuel performance capabilities to more accurately model these phenomena; multiphysics simulations have also been conducted to determine the power and burnup histories of the HBu fuel, which are needed as inputs for the fuel performance calculations. Most recently, new statistical approaches have been developed to identify a subset of fuel rods that have greater FFRD susceptibility, reducing the total number of fuel performance simulations required. Prior LOCA simulations have relied on the TRACE systems code, which can model the core and primary loop during accident conditions. TRACE includes many models for various aspects of the primary loop, but two sets of models are important for this report. First, TRACE uses a lumped-fuel approach for modeling the core. This approximates the ~50,000 fuel rods in the core with a much smaller number of rods. The rods can be lumped in various ways as determined by the user. For example, one lumped rod may be used to represent all rods in an assembly, sometimes with an additional rod representing the hottest fuel rod. However, due to runtime constraints and complexity of modeling, a more common approach is to group several assemblies or larger regions of the core into single lumped rods. These lumping schemes apply not only to fuel rods but to flow channels as well. Second, TRACE has several different models for treating decay heat, ranging from pregenerated decay heat curves based on an ANSI/ANS-5.1 standard (hereinafter abbreviated simply as ANSI) to explicit time-dependent heat inputs from the user. None of these models account for differences in isotopics between different rods, which is an approximation the work in this report seeks to eliminate. This report focuses on the implementation of coupled decay heat capabilities in the Virtual Environment for Reactor Applications (VERA) code suite to address a gap identified in previous LOCA simulations. This constitutes an improvement for both the lumped-fuel and decay heat models in TRACE. VERA has been developed to perform high-fidelity, whole-core multiphysics simulations for LWRs. Previously, during the Consortium for Advanced Simulation of LWRs (CASL) program, the emphasis was on providing accurate steady-state analysis—with a secondary focus on reactivity insertion accident (RIA) analysis—to address operational challenges in the nuclear energy industry. Under the Department of Energy (DOE) Nuclear Energy Advanced Modeling and Simulation (NEAMS) program, these capabilities are being extended to a broader range of transient analyses with the goal of quantifying the risk of fuel failures such as FFRD. To properly model such conditions with VERA, decay heat calculations have been integrated with the multiphysics to enable rod-by-rod thermal hydraulic (TH) conditions to be driven by the decay heat in long-running accidents such as LOCAs.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Scoping Study of Integrated Geothermal CO 2 Heat Pump and Water Well System in Cold Climate Region (CRADA Final Report)

This study evaluates the feasibility of using ground-source heat pumps (GSHPs) integrated with water wells for residential heating demands in cold regions of the United States. Four different heat pump systems were evaluated and compared: a CO 2 air-source heat pump (ASHP), a R-410A ASHP, a CO 2 GSHP integrated with well water, and a R-410A GSHP integrated with well water. Simulations were conducted at both equipment and building integration levels, followed by a nationwide analysis across 10 selected cities. Results indicate that integrating GSHP technology with existing water wells (e.g., artesian, bedrock, drilled, and collector wells) is a feasible heating solution because of their high flow rates, good water quality, stable temperatures, and low environmental impact. Although R-410A systems demonstrate higher efficiency, CO 2 systems are more suitable for heating from contamination-free and energy security perspective. The CO 2 GSHPs maintain better performance in colder climates compared with that of ASHPs, providing higher coefficient of performance and environmental benefits because CO 2 refrigerant leakage would not contaminate well water. A national analysis confirms that CO 2 GSHPs outperform furnaces, especially in cold climates, making them a promising solution for residential heating.

15 GEOTHERMAL ENERGY↗