SEARCH · Engineering Papers

Results for “steam data”

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.

SourceResearch connectionFrom yearThrough year

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

At least 73 records · Page 4

All sources NASA NTRS DOE OSTI

NASA NTRS2002

Effect of Environment on the Stress- Rupture Behavior of a C/SiC Composite Studied

Advanced reusable launch vehicles will likely incorporate fiber-reinforced ceramic matrix composites (CMC's) in critical propulsion and airframe components. The use of CMC's is highly desirable to save weight, improve reuse capability, and increase performance. One of the candidate CMC materials is carbon-fiber-reinforced silicon carbide (C/SiC). In potential propulsion applications, such as turbopump rotors and nozzle exit ramps, C/SiC components will be subjected to a service cycle that includes mechanical loading under complex, high-pressure environments containing hydrogen, oxygen, and steam. Degradation of both the C fibers and the SiC matrix are possible in these environments. The objective of this effort was to evaluate the mechanical behavior of C/SiC in various environments relevant to reusable launch vehicle applications. Stress-rupture testing was conducted at the NASA Glenn Research Center on C/SiC specimens in air and steam-containing environments. Also, the oxidation kinetics of the carbon fibers that reinforce the composite were monitored by thermogravimetric analysis in the same environments and temperatures used for the stress-rupture tests of the C/SiC composite specimens. The stress-rupture lives obtained for C/SiC tested in air and in steam/argon mixtures are shown in the following bar chart. As is typical for most materials, lives obtained at the lower temperature (600 C) are longer than for the higher temperature (1200 C). The effect of environment was most pronounced at the lower temperature, where the average test duration in steam at 600 C was at least 30 times longer than the lives obtained in air. The 1200 C data revealed little difference between the lives of specimens tested in air and steam at atmospheric pressure.

Verrilli, Michael J.↗

DOE OSTI2018

U 3 Si 2 behavior in H 2 O: Part I, flowing steam and the effect of hydrogen

Recent interest in U 3 Si 2 as an advanced light water reactor fuel has driven assessment of numerous properties, but characterization of its response to H 2 O environments is absent from the literature. The behavior of U 3 Si 2 in H 2 O containing atmospheres is investigated and presented in a two-part series of articles aimed to understand the degradation mechanism of U 3 Si 2 in H 2 O. Reported here are thermogravimetric data for U 3 Si 2 exposed to flowing steam at 250–470 °C. Additionally the response of U 3 Si 2 to flowing Ar-6% H 2 from 350 to 400 °C is presented. Microstructural degradation is observed following hours of exposure at 350 °C in steam. U 3 Si 2 undergoes pulverization on the timescale of minutes when temperatures are increased above 400 °C. In conclusion, this mechanism is accelerated in flowing Ar-H 2 at the same temperatures.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2018

Scaling Studies for Advanced High Temperature Reactor Concepts, Final Technical Report: October 2014—December 2017

Computer simulations of nuclear reactor thermal-hydraulic phenomena are often used in the design and licensing of nuclear reactor systems. In order to assess the accuracy of these computer simulations, computer codes and methods are often validated against experimental data. This experimental data must be of sufficiently high quality in order to conduct a robust validation exercise. In addition, this experimental data is generally collected at experimental facilities that are of a smaller scale than the reactor systems that are being simulated due to cost considerations. Therefore, smaller scale test facilities must be designed and constructed in such a fashion to ensure that the prototypical behavior of a particular nuclear reactor system is preserved. The work completed through this project has resulted in scaling analyses and conceptual design development for a test facility capable of collecting code validation data for the following high temperature gas reactor systems and events— 1. Passive natural circulation core cooling system, 2. pebble bed gas reactor concept, 3. General Atomics Energy Multiplier Module reactor, and 4. prismatic block design steam-water ingress event. In the event that code validation data for these systems or events is needed in the future, significant progress in the design of an appropriate integral-type test facility has already been completed as a result of this project. Where applicable, the next step would be to begin the detailed design development and material procurement. As part of this project applicable scaling analyses were completed and test facility design requirements developed. Conceptual designs were developed for the implementation of these design requirements at the Oregon State University (OSU) High Temperature Test Facility (HTTF). The original HTTF is based on a ¼-scale model of a high temperature gas reactor concept with the capability for both forced and natural circulation flow through a prismatic core with an electrical heat source. The peak core region temperature capability is 1400°C. As part of this project, an inventory of test facilities that could be used for these experimental programs was completed. Several of these facilities showed some promise, however, upon further investigation it became clear that only the OSU HTTF had the power and/or peak temperature limits that would allow for the experimental programs envisioned herein. Thus the conceptual design and feasibility study development focused on examining the feasibility of configuring the current HTTF to collect validation data for these experimental programs. In addition to the scaling analyses and conceptual design development, a test plan was developed for the envisioned modified test facility. This test plan included a discussion on an appropriate shakedown test program as well as the specific matrix tests. Finally, a feasibility study was completed to determine the cost and schedule considerations that would be important to any test program developed to investigate these designs and events.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

NASA NTRS1987

Compatability of dispersion-strengthened platinum with resistojet propellants

Resistojets for the Space Station require long life and multipropellant capability. The choice of available materials to meet these requirements is limited. Dispersion-strengthened platinum was selected. Past results indicated that it should be suffieiently inert in candidate propellant environments and should be capable of operating at moderate temperatures for extended periods. A series of propellant compatibility tests was done with platinum strengthened with either yttria or zirconia. Data presented included the results of 1000-hr tests in CO2, H2, ammonia (NH3), N2, steam, hydrazine (N2H4), and methane (CH4); and 2000-hr tests in H2 and NH3. The platinum samples were tested at 1400 C in CO2, H2, NH3, N2, steam, and N2H4; at 500 C in CH4; and at 800 C in N2H4. The mass-loss results indicated material life, exptrapolated from experimental mass-loss data, in excess of 100 000 hr in all environments except steam and N2H4, where it was greater than or =45000 hr. Generally, on the basis of mass loss, there were no compatibility concerns in any of the environments considered. Optical and scanning electron microscopy were used to determine the effect of propellants on the material surface and to evaluate material stability.

Whalen, Margaret V.↗

DOE OSTI2021

Determination of oxidation rates and volatile oxidation products for HTGR graphite matrix material exposed to steam atmospheres

High-temperature gas-cooled reactors (HTGRs) in operation use tristructural isotropic (TRISO) particles embedded in graphite and carbonized resin matrix to form the fuel element. This graphite matrix material serves as a supportive structural element, heat transfer medium, and neutron moderator. In HTGR designs, fuel compacts are exposed to helium coolant, which facilitates high outlet temperatures (750°C 2 O, 800°C 2 , and H 2 , are quantified in varied oxidant atmospheres using a coupled thermogravimetric analyzer and mass spectrometer. Furthermore, oxidation rates reported here for varied steam (H 2 O [g]) atmospheres are predominantly linear and comparable with literature values in the range of tested temperatures (800–1200°C). Changes in dominant matrix oxidation products from primarily CO to a mixture of CO, CO 2 , and H 2 were observed at higher temperatures (≥1000°C) and steam atmospheres (≥5 kPa pH 2 O). Kinetic data indicates that there was no shift in oxidation regime with chemical oxidation occurring at all temperatures and H2O (g) atmospheres tested. These data provide insight into the oxidation behavior of graphite matrix material and will inform future testing conditions, notably mixed atmospheric conditions, of HTGR fuel elements.

36 MATERIALS SCIENCE↗

DOE OSTI2024

In-situ strain behavior and BISON simulations of Zircaloy cladding subjected to temperature cycling separate-effects tests in a steam environment

Understanding fuel system performance during anticipated transients without scram (ATWSs) in boiling water reactors (BWRs) is necessary for refining current and future safety limits. High-fidelity material models and simulations are fundamental to rigorous assessment of zirconium-based cladding performance. However, experimental thermomechanical data during simulated ATWSs to validate these modes are limited. To provide relevant in-situ data, Zircaloy-4 cladding was subjected to cyclic heating in a steam environment to simulate an out-of-pile BWR ATWS. Digital image correlation was used to capture the cladding strain behavior in-situ for comparison against simulations using the BISON finite element code. Conventional high-temperature models were compared using multiple schemes to gain a better understanding of the applicability of three BISON models to BWR ATWS: (1) the default combination of creep models in BISON, (2) the high-temperature Erbacher model alone, and (3) the low-temperature Limback-Andersson model alone. The cases run with the Limback-Andersson model alone produced the lowest root mean square error (RMSE). The lowest RMSE for the Limback-Andersson model alone was 0.659%, and the highest RMSE reported was 4.22%. A data gap within the model in the temperature regime of interest was also identified, and to account for this gap, the current model in BISON is linearly interpolated between two separate datasets. In conclusion, this evaluation highlights the need to either develop a new model or to improve the existing model to capture transient creep effects resulting from a cyclic temperature transient.

Anticipated transient without SCRAM↗

DOE OSTI2020

ICME for Creep of Ni-Base Superalloys in Advanced Ultra-Supercritical Steam Turbines

The goal of this project contains three major aspects: (1) critical assessment of existing experimental data, (2) critical assessment of existing modeling capabilities and (3) development of new modeling capabilities that are critical but currently missing in predicting long-term creep behavior of Ni-base superalloys used in advanced ultra- supercritical (A-USC) steam turbines for coal-fired power plants. The project uses advanced materials informatics to datamine the experimental data, uncertainty quantification tools to rigorously assess existing creep-life models, and integration of phase-field and FFT-based crystal plasticity to develop a multi-scale, physics-based, microstructure-sensitive creep model.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2021

Performance evaluation of a Terry GS-2 steam impulse turbine with air-water mixtures

Terry steam turbines are widely used in various industries because of their robust design. Within the nuclear power generation industry, they are used in the Reactor Core Isolation Cooling System to remove decay heat during reactor isolation events. During the Fukushima Daiichi nuclear power station disaster in Japan in 2011, the Reactor Core Isolation Cooling System and associated Terry turbine operated for over 70 hours in Unit 2; this runtime is well beyond the expected operating duration. Theories suggest the turbine was subjected to a two-phase inlet flow, which could degrade the turbine performance. In this work, an experimental test rig was constructed to test a full-scale Terry model GS-2 steam turbine under two-phase air/water flows. Steady-state efficiency and torque performance maps of the turbine were developed over a range of turbine inlet pressures (1.38–4.83 bar or 20–70 psia), air mass fractions (0.05–1.0) and rotational speeds up to 4000 RPM. Furthermore, turbine performance followed expected trends with torque varying linearly and efficiency varying quadratically with rotational speed. In addition, high-speed images of the two-phase flow entering the turbine were also analyzed to understand how changes in inlet pressure and air mass fraction affect the flow regime and homogenization. The present tests with air–water two-phase mixtures are an important step towards providing an understanding of the full-scale Terry turbine’s behavior and performance curves under two-phase conditions. The results of this work will be combined with air/water and steam/water data gathered using a small-scale Terry ZS-1 steam turbine in order to understand the scaling relationship between large and small size Terry turbines and fluid pairs. The combined data set will enable further development of analytical models over a wide range of conditions and may be used to provide technical justification for expanded use of the Terry turbines in nuclear power plant safety systems and other systems.

42 ENGINEERING↗

DOE OSTI2022

Flow structures of the cross-flow over a five-layer helically coiled steam generator geometry

The helically-coiled heat exchanger (HCSG) offers advantages over straight tubes such as compactness in geometry, increased heat transfer coefficients, and capability to absorb thermal expansion. In this study, the time-resolved velocity field data of shell-side crossflow over a five-layer helically coiled steam generator geometry was obtained using Particle Image Velocimetry (PIV) between adjacent rods in four regions with up to 5000 frames per second (5 kHz) at approximately Re u = 3600. The slant rod bundle created different flow patterns in different regions. Proper Orthogonal Decomposition (POD) revealed high-energy-mode flow structures. Due to the confined flow channel geometry, the large flow structures were not advected resulting in no strong POD mode paring. Continuous Wavelet Transform (CWT) visualized the characteristics of flow fluctuation in time and frequency domain simultaneously, which ranged in Strouhal number, S u , between 0.03 and 1.17. In the wake regions of the rods, flows changed in both pattern and magnitude over time. Once a pattern formed, it continued for relatively shorter than straight tube arrays, before changing the pattern again. The histograms of the POD time coefficients presented this multimodal flow characteristics. The current study focuses more on whole flow field analyses in the selected regions rather than local point-wise analyses. Finally, this study revealed that various Strouhal numbers can exist in the helically coiled heat exchanger geometry, which was not observed in straight tube arrays. In particular, Strouhal numbers smaller than 0.1 do not seem to be caused by vortex shedding but seem to be the result of the combination of complex geometry and possible multimodal trends. Based on the current observation, further works would involve intensive instantaneous point-wise analyses on the interactions between important locations such as separation points, stagnation points, shear layers, etc.

42 ENGINEERING↗

DOE OSTI2018

Demonstration of Fully Coupled Calculations in Helical Steam Generator: Toward Predictions of Fluid Elastic Instability

The NEAMS program aims to develop an integrated multi-physics simulation capability “pellet-to-plant” for the design and analysis of future generations of nuclear power plants. In particular, the Reactor Product Line code suite's multi-resolution hierarchy is being designed to ultimately span the full range of length and time scales present in relevant reactor design and safety analyses, as well as scale from desktop to petaflop computing platforms. Flow-induced vibration (FIV) is widespread problem in energy systems because they rely on fluid movement for energy conversion. Vibrating structures may be damaged as fatigue or wear occurs. Given the importance of reliable components in the nuclear industry, flow-induced vibration has long been a major concern in safety and operation of nuclear reactors. In particular, nuclear fuel rods and steam generators have been known to suffer from flow-induced vibration and related failures. Advanced reactors, such as integral Pressurized Water Reactors (PWRs) considered for Small Modular Reactors (SMR), often rely on innovative component designs to meet cost and safety targets. One component that is the subject of advanced designs is the steam generator, some designs of which forego the usual shell-and-tube architecture in order to fit within the primary vessel. In addition to being more cost- and space-efficient, such steam generators need to be more reliable, since failure of the primary vessel represents a potential loss of coolant and a safety concern. A significant amount of data exists on flow-induced vibration in shell-and-tube heat exchangers, and heuristic methods are available to predict their occurrence based on a set of given assumptions. In contrast, advanced designs have far less data available. Advanced modeling and simulation based on coupled structural and fluid simulations have the potential to predict flow-induced vibration in a variety of designs, reducing the need for expensive experimental programs, especially at the design stage. Over the past seven years, the Reactor Product Line has developed the integrated multi-physics code suite SHARP. The goal of developing such a tool is to perform multi-physics neutronics, thermal/fluid, and structural mechanics modeling of the components inside the full reactor core or portions of it with a user-specified fidelity. In particular SHARP contains high-fidelity single-physics codes Diablo for structural mechanics and Nek5000 for fluid mechanics calculations. Both codes are state-of-the-art, highly scalable tools that have been extensively validated. These tools form a strong basis on which to build a flow-induced vibration modeling capability. In the last two years a significant effort was devoted to 1) develop and validate a fully coupled capability in SHARP for Fluid-Structure calculations (FSI) and 2) validate the use of SHARP for one-way coupled calculations in helical steam generators on legacy data available as well as novel experiments. In this report we discuss an extension of previous one-way coupled calculations performed with Nek5000 and Diablo aimed at simulating available FIV experiments in helical steam generators in the turbulent buffeting regime. It was demonstrated that in the buffeting regime one-way coupling was judged sufficient because the pressure loads do not cause substantial displacements. However, higher speeds led to a reduction in accuracy and the need for a fully coupled capability for velocity or approaching the critical velocity and fluid elastic instability. In this report we demonstrate such fully coupled capability on the Argonne test case discussed in previous reports.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2022

Predictive modeling of a subcritical pulverized-coal power plant for optimization: Parameter estimation, validation, and application

As renewable power generation deployment increases, fossil fuel plants are increasingly required to operate more flexibly. Many coal-fired power plants were originally designed to operate at base load and do not operate optimally at partial load. Predictive first-principles plant-wide models can be employed to identify opportunities for flexibility improvements and diagnose low-load operating issues. This paper describes the application of the Institute for the Design of Advanced Energy Systems Integrated Platform (IDAES) to model and optimize flexible power plant operations. The key benefits of using IDAES are that it provides an open-source, fully equation-oriented modeling framework for efficient modular model construction, reuse, and customization, together with a mathematical optimization framework leveraging powerful, state-of-the-art solvers. The process systems engineering workflow from predictive process simulation to parameter estimation, model validation, and plant optimization is applicable to a variety of existing and next-generation energy systems as well as other chemical and environmental processes. Here, to demonstrate this capability, a physics-based, steady-state model was developed to improve full- and part-load performance of the Escalante Generating Station, a 245 MWe (net) subcritical pulverized coal-fired power plant owned and operated by Tri-State Generation and Transmission Association. Specifically, sixty-nine model parameters were simultaneously estimated from several months of operating data enabling prediction of flow rates, temperatures, pressures, and steam quality throughout the plant. The validated model was leveraged by Escalante to reduce the minimum operating load from 90 MW to 50 MW by diagnosing a low-load water-hammer issue, enabling coal usage and emissions reductions during periods of low power demand. Additionally, opportunities for heat rate reduction (i.e., efficiency improvement) through a steeper sliding-pressure approach to load-following and optimization of other boiler operating variables were also identified and quantified. For example, a potential efficiency improvement of 0.7 percentage points was observed at half-load operation.

01 COAL, LIGNITE, AND PEAT↗

NASA NTRS1972

Smoke Plume Analysis Using Fan-beam and Single-beam Radiometers

Smoke plume data were taken using the stacks of the Mills Road Steam Plant on Redstone Arsenal, Huntsville, Alabama. The fan-beam unit was placed approximately 235 meters east of the Mills Road Steam Plant, and the single-beam unit was placed approximately 80 meters north of the fan-beam unit. Results of the smoke plume measurements indicate that the smoke plume is a periodic process near the mouth of the smokestack. The usefulness of the system is limited because of inaccurate and cumbersome positioning methods and base line constraints due to cable length. It is recommended that the radiometers be mounted on pedestals which have both azimuth and elevation positions determined by digitally controlled stepper drive motors. It is also recommended that a time multiplex system be used to transmit data from the radiometers to the electronics van.

Dodd, J. L.↗

DOE OSTI2018

Industrial Scale Demonstration of Smart Manufacturing, Achieving Transformational Energy Productivity Gains

While many U.S. manufacturing operations utilize optimization for individual unit processes, smart manufacturing (SM) systems that integrate manufacturing intelligence in real time across an entire production operation are rare in large companies and virtually nonexistent in smaller organizations. One example of an area where SM systems can be applied is in the management of waste heat. A smart system that not only seeks to recover waste heat, but also to use energy more efficiently, is a more cost-effective approach because energy use, waste energy loss and product output are optimized together. The overall objective of this project was to develop an industry-accepted SM Platform that enables smart systems by accelerating and lowering the cost of development and implementation scales for use in diverse sets of manufacturing industry sectors, manufacturing operations and company sizes. Specifically, the project (1) designed and demonstrated the application of a prototype SM Platform for two diverse commercial test beds, (2) demonstrated at one and estimated for the other test bed the potential reduction in waste heat generation, and (3) worked with leading automation vendors to catalyze low-cost commercialization of the technology developed. The Smart Manufacturing Application and Data Platform (SM Platform) developed during this project is an innovative approach that marries IT virtualization technologies with operational data and modeling system requirements to construct a ready-to-go platform for enabling sensor – data – modeling – actuation systems, driven by real-time plant data and performance metrics. This SM Platform allows manufacturing organizations, regardless of their industry or size, to assemble new operational systems at a much lower cost, optimizing process knowledge and improving energy productivity by integrating with existing process control and automation systems. Also developed during this project is a methodology for developing energy productivity metrics that use real-time process information and provide comparisons for potential, practical, and actual performance, as well as examples and the methodology for provisioning of an Energy Dashboard that displays alternatives to optimize energy use within specific business contexts aimed at helping improve energy productivity and reduce emissions in U.S. manufacturing. The SM Platform designed utilizes current manufacturing, operational and IT industry standards. The platform can be used to expedite sensor – data – model – actuation system development and deployment in a cloud-based environment using a novel end-to-end workflow as a service capability that is already integrated with data connection, ingestion, and contextualization services. In addition, the methodology for development of energy productivity metrics and reusable application templates called Toolkits have been defined so that they can be tailored to a specific business situation. The project’s two test beds, one in a hydrogen production plant and the other in a forging, heat treatment, and machining operation, utilize sensor-driven modeling, measurement, and simulation systems. In these two test beds, the implementation of these as a comprehensive system has made it possible for energy productivity to be managed in real-time throughout the plant and enterprise using an energy dashboard. The development pathway to direct machine actuation was articulated. During the first year, the project team developed the most highly instrumented steam-methane reformer (SMR) in the U.S. using infrared cameras and thermocouples. Real-time data are streamed to high fidelity and reduced-order models for analysis. A high fidelity CFD model, parallelized in the SM Platform cloud environment, was demonstrated for operational use. This is the first real-time operational productivity system of a steam methane reformer using both high fidelity and data-driven models together in a real time situation to balance natural gas flow to the reformer tubes. An infrared camera system was developed and shown to outperform thermocouples in coverage, accuracy, reliability, and cost effectiveness for use in a high temperature, harsh environment. A forging, heat-treating, machining line operation test bed includes new instrumentation for data capture analysis, modeling, and simulation and will be integrated into SM Platform workflows so that business performance can be managed in real-time. Composable metrics were developed using the SM Platform to drive improvements in energy productivity, environmental performance, safety, asset management, costs, and overall operations. A major focus of the SM systems developed was optimization of energy productivity at the enterprise level, which resulted in reductions in waste heat generation for the two project test beds. Reductions in the waste heat generated will result in greater energy savings than will waste heat recovery due to inefficiencies in the heat transfer process. For the SMR test bed an efficiency improvement of 1 – 2% with a corresponding waste heat reduction of 5% were demonstrated. It should be noted that the test bed SMR unit had an efficiency of more than 90% as compared to 70 to 80% efficiencies of most SMR units. So implementation of similar SM systems at typical SMR units could yield more than 15 to 25% waste heat reductions. Similarly the forging, heat-treating, machining line operation test bed is a DOE AMO Platinum Level Superior Energy Performance plant with a much higher than typical overall operating efficiency. For this test bed heat integration using recuperators is estimated to result in fuel savings of 15.9% due to waste heat recovery compared to the base case without recuperators with negligible changes in part exit conditions. This results in an 18.9% energy efficiency improvement. The project team estimates that broad multi-sector adoption of the developed technology could reduce waste heat generation by an amount equivalent to 1.3% of total U.S. energy use. This waste heat reduction is associated with 69 million tons reduction in annual carbon dioxide emissions. Other potential benefits include reducing process times, solid and liquid wastes, environmental impacts, and water use. It is estimated that this investment has an anticipated payback period of less than one year in energy-intensive applications. The SM Platform could also reduce the costs of deploying SM systems by 50% in manufacturing operations. Commercialization of the SM Platform will require significant cross-industry collaboration and technology provider market changes. Steps taken toward commercialization included 1) analyzing savings from deployment of the SM Platform and 2) holding SM Platform workshops, webinars, and conferences with targeted individual industry segments, with a focus on small and medium-sized organizations. An upgraded community website has been established as a portal for accessing and distributing information. Most importantly, the SM platform enabling technology developed during this project and its commercialization will continue, evolve and expand under the Clean Energy Smart Manufacturing Innovation Institute (CESMII).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

Application of Sequential Design of Experiments (SDoE) to Large Pilot-Scale Solvent-Based CO2 Capture Process at Technology Centre Mongstad (TCM)

The United States Department of Energy’s Carbon Capture Simulation for Industry Impact (CCSI2) program has developed a framework for sequential design of experiments (SDoE) that aims to maximize knowledge gained from budget- and schedule-limited pilot scale testing. SDoE was applied to the planning and execution of campaigns for testing CO2 capture systems at pilot-scale in order to optimally allocate resources available for the testing. In this methodology, a stochastic process model is developed by quantifying the parametric uncertainty in submodels of interest; for a solvent-based CO2 capture system, these may include physical properties and equipment performance submodels (e.g., mass transfer, interfacial area). This uncertainty is propagated through the full process model, over variable operating conditions, for estimating the resulting uncertainty in key model outputs (e.g., percentage of CO2 capture, solvent regeneration energy requirement). In developing a data collection plan, the predicted output uncertainty is incorporated into an algorithm that seeks simultaneously to select process operating conditions for which the predicted uncertainty is relatively high and to ensure that the entire space of operation is well represented. This test plan is then used to guide operation of the pilot plant at varying steady-state conditions, with resulting process data incorporated into the existing model using Bayesian inference to refine parameter distributions. The updated stochastic model, with reduced parametric uncertainty from data collected, is then used to guide additional data collection, thus the sequential nature of the experimental design. The SDoE process was implemented at the pilot test unit (12 MWe in scale) at Norway’s Technology Centre Mongstad (TCM) in a summer 2018 test campaign with aqueous monoethanolamine (MEA). During the test campaign, the varied operating conditions included the flowrates of circulated solvent, flue gas, and reboiler steam and the CO2 concentration in the flue gas. The process data were used to update probability distributions of mass transfer and interfacial area parameters of a stochastic process model developed by the CCSI2 team. Two iterations of the SDoE process were executed, resulting in the uncertainty in model predicted CO2 capture percentage decreasing by an average of 58.0 ± 4.7% over the full input space of interest. This work demonstrates the potential of the SDoE process for model refinement through reduction in process model parametric uncertainty, and ultimately risk in scale-up, in CO2 capture technology performance.

carbon capture↗

DOE OSTI2019

High-Fidelity Simulation of Flow-Induced Vibrations in Helical Steam Generators for Small Modular Reactors

Flow-induced vibration (FIV) is a widespread problem in energy systems as they rely on fluid movement for energy conversion. Vibrating structures may be damaged as fatigue or wear occur. Given the importance of reliable components in the nuclear industry, FIV has long been a major concern in the safety and operation of nuclear reactors. In particular, nuclear fuel rods and steam generators have been known to suffer from FIV and related failures. In this paper we discuss the use of the computational fluid dynamics code Nek5000 coupled to the structural code Diablo to simulate the flow in helical coil heat exchangers and associated FIV. In particular, one-way coupled calculations are performed, where pressure and tractions data are loaded into the structural model. The main focus of this paper is on validation of this capability. Fluid-only Nek5000 large eddy simulations are first compared against dedicated high-resolution experiments. Then, one-way coupled calculations are performed with Nek5000 and Diablo for two data sets that provide FIV data for validation. These calculations were aimed at simulating available legacy FIV experiments in helical steam generators in the turbulent buffeting regime. In this regime one-way coupling is judged sufficient since the pressure loads do not cause substantial displacements. It is also the most common source of vibration in helical steam generators at the low flows expected in integral pressurized water reactors. We discuss validation of two-way coupled experiments and benchmarks toward the simulation of fluid elastic instability. We briefly discuss the application of these methods to grid-to-rod fretting.

Flow-Induced Vibration↗

DOE OSTI2018

Global Value Chain and Manufacturing Analysis on Geothermal Power Plant Turbines

In this study, we have undertaken a robust analysis of the global supply chain and manufacturing costs for components of Organic Rankine Cycle (ORC) Turboexpander and steam turbines used in geothermal power plants. We collected a range of market data influencing manufacturing from various data sources and determined the main international manufacturers in the industry. The data includes the manufacturing cost model to identify requirements for equipment, facilities, raw materials, and labor. We analyzed three different cases; 1) 1 MW geothermal ORC Turboexpander 2) 5 MW ORC Turboexpander 3) 20 MW geothermal Steam Turbine

15 GEOTHERMAL ENERGY↗

DOE OSTI2023

Microstructural analysis of tristructural isotropic particles in high-temperature steam mixed gas atmospheres

High-temperature gas-cooled reactors (HTGRs) use tristructural isotropic (TRISO) particles embedded in a graphitic matrix material to form the integral fuel element. Potential off-normal reactor conditions for HTGRs include steam ingress with temperatures above 1,000 °C. Fuel element exposure to steam can cause the graphitic matrix material to evolve, forming an atmosphere composed of oxidants and oxidation products and potentially exposing the TRISO particles to these conditions. Investigating the oxidation response of TRISO particles exposed to a mixed gas atmosphere will provide insight into the stability under off-normal conditions. In this study, surrogate TRISO particles were exposed to high temperatures (T = 1,200 °C) in flowing steam (3% < pH 2 O < 21%) and CO (pCO < 1%) to determine the oxidation behavior of the SiC layer when exposed to various mixed gas atmospheres. Scanning electron microscopy, x-ray diffraction, and focused ion beam milling was used to determine the impact of CO and steam on the oxidation behavior of the SiC layer. Therefore, the data presented demonstrates how the SiC layer showed strong oxidation resistance due to limited SiO 2 growth and maintained its structural integrity under these off-normal conditions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Site Integration and Regulatory Considerations for a Nuclear Power Plant Colocated with Industrial Facilities: Colocation Studies for a Petroleum Refinery, Methanol Plant, and Wood Pulp Plant

This research explores the colocation of nuclear power plants (NPPs) with industrial applications. Three existing industrial sites were considered to demonstrate the siting process and illuminate technological gaps for future work. The three applications demonstrated for colocation here are a petroleum refinery, a methanol production plant, and a pulp and paper plant. This study uses a modified version of the EPRI siting criteria to explore the geological and demographic characteristics of the location of the current industrial site, as well as exploring external hazards from the industrial plant and its surrounding land use. Data was collected from public databases to estimate site characteristics. We then discuss how the site characteristics may impact the ability to colocate an NPP with an industrial application. The application site and 5 additional sites were explored for each application to give a general indication of the siting implications for an NPP in each area. The hazards for each industrial application was also explored to determine how colocation may impact reactor safety. The following gaps have been identified and should be explored in future research on colocation of NPPs with petroleum refineries, methanol plants, and pulp and paper plants: - There is a variety of industrial use, hazards, and pipelines in the surrounding area. A more thorough review of these hazards should be considered for colocation. - In general, the whole region around some applications seems to have softer soil, with implications for large site preparation costs. Further site investigations should prioritize looking into the geotechnical conditions. - Applications along coastlines are susceptible to flooding and hurricanes. The benefits of colocation should be weighed against the potential design implications. - The benefits of natural gas pipeline infrastructure in place should be explored further. If heat supply from the NPP is not required or not feasible due to the distance between the NPP and the application, there may be an opportunity to supply hydrogen to the plant through an existing pipeline. - Because there are several collocated industrial plants in the regions for the refinery and methanol plant, the benefits of sharing resources from the NPP should be explored further. This may open up additional sites for colocation. The following knowledge gaps were identified for the colocation of NPPs with these three industries, and industrial applications in general. These gaps are: - While the STAND tool contains many important characteristics for the reactor siting process, it is not calibrated for the colocation of NPPs with industrial facilities. - There are aspects of both the NPP and industrial application that need to be quantified for a siting analysis. Particularly, we need to understand the water intake requirements for NPPs and each application. - Further work may focus on adapting the STAND site comparison methodology to comparison of sites for co-location. This will involve using the data documented in this report as a starting point and performing a comprehensive and quantitative comparison. - Without spending significant resources, it would be impossible to gather data for each site to evaluate all aspects of siting. One approach to finding data and understanding its implications to siting is looking at FSARs for existing plants. For example, most sites considered in this study have small Vs30 values, indicating soft soil. However, there are NPPs located in the vicinity of most of the sites (e.g., Waterford Steam Electric Station near New Orleans) and reviewing available site characteristics and geotechnical data for these NPPs, might provide further information for siting. - The siting analysis in this study indicates that colocation of the NPP with the industrial site could be difficult based on external hazards, cooling requirements, weather, or population. We need to determine the impact of distance between the two facilities on cost and quality of energy transport. - This study did not touch on socioeconomic impacts for NPP colocation with industrial facilities. The input-output analysis methodology could be applied to the communities referenced in this study to determine the socioeconomic impact of these projects. - Similarly, the impacts of colocation on emergency planning was not explored in this study. The impacts on emergency planning infrastructure are somewhat related to the socioeconomic impacts, and could be explored using a similar methodology. - This study also did not address physical and cybersecurity, which will be important aspects of co-location [ref] . Cybersecurity will be important, regardless of the distance, but physical security will be important if the facilities are located very closely. Physical security might also be important for the steam lines between the plants, unless they are determined to be non-safety significant. - In many site l

08 HYDROGEN↗