Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “heat flow”

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 811 records · Page 45
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Preparation of illite coated geomaterial microfluidic surfaces: Effect of salinity and heat treatment

Unique characteristics of clay (e.g., high surface area, deficiency in positive charges) make any clay abundant shales a good source of adsorbed gas. However, the presence of clay in porous media can also affect shale rock's producibility. The clay-water interaction can cause significant swelling and fines migration in the formation and impair the overall hydrocarbon recovery from shale. Geomaterial micromodels, developed by functionalizing traditional glass or PDMS surfaces with geomaterials (e.g., calcite, Quartz, clay), can represent the physicochemical properties of the natural porous media and have been used during the last few years to understand and evaluate the solid-fluid physicochemical interactions. Here, this study focuses on developing a clay-coated geomaterial surface and investigates the effect of base fluid's salinity on clay adsorption to the glass surface. Glass capillary tubes and straight channel borosilicate glass micromodels are coated with Illite clay to represent the pore-scale clay chemistry of Caney Shale, a Mississippian unconventional play in Southern Oklahoma, USA. 10 wt% of Illite clay slurries made with brines of four different salinities are used to coat the glass-capillary tubes to understand the effect of salinity in clay adsorption on the glass surface and overall coating quality. To achieve a stable coating and evaluate the impact of heat treatment on coating's stability, straight channel glass flow cells coated with Illite clay are heat-treated at low (25 °C) and high temperature (125 °C), and the results are compared with an untreated coated surface. Flooding tests were carried out with brines of different salinities on the coated surface to evaluate the stability of the coating. The experimental results indicated a strong relationship between the brine's salinity and the adsorption of clay particles on the glass surface. An increase in brine concentration resulted in improved adsorption of clay particles on the glass surface. Experiments involving heat treating the glass surface following the coating demonstrated significant improvement in the stability of the coating.

02 PETROLEUM↗
DOE OSTI2022

Measurement of Convective Heat Transfer Coefficients with Supercritical CO2 in Novel Additively Manufactured Helically Patterned Pin Fin Tubes Using the Wilson Plot Technique

This paper describes the measurement of convective heat transfer coefficients and friction factors for sCO2 flowing in pin-fin patterned pipes in the Heat Exchange and Experimental Testing (HEET) facility at the US DoE’s National Energy Technology Laboratory (NETL) in Morgantown, WV. The measurement procedures in the HEET rig were validated by conducting benchmark tests with smooth stainless-steel tube and comparing the results with published correlations for Nusselt number (Nu) and friction factor. Over typical Reynolds number range in sCO2, the measured Nu and friction factors were within 7% of classical correlations for smooth tube flow.The candidate pin fin patterned pipes were additively manufactured (AM) at the Oak Ridge National Laboratory. The pins were circular or elliptical in cross-section. Pin length to diameter aspect ratios were 1.33 and 2, while the pin diameter to tube diameter ratio was 0.188 and 0.125. Tests were performed for ReD varying from 6.9×104 to 2.2×105 and at conditions equivalent to the low pressure outlet (8.69 MPa, 361 K) of the low temperature recuperator (LTR) in an indirect sCO2 power cycle. The Wilson plot technique was utilized to measure the bulk heat transfer coefficients.For the better performing design (tube A, pin length to tube diameter ratio: 1.33, pin diameter to tube diameter ratio: 0.188), the local heat transfer coefficient increased by 112% relative to the Dittus-Boelter correlation at the LTR low pressure outlet. This corresponded to a 282% increase in the product of the heat transfer coefficient and the surface area. Large pressure drops across the test articles were observed.

Searle, Matthew↗
DOE OSTI2021

PREPARATION OF CLAY-COATED GLASS SURFACES FOR MICROFLUIDICS-BASED STUDY ON CLAY-FLUID INTERACTIONS

Unique characteristics of clay, even though make any clay abundant shales a good source of adsorbed gas, make them equally difficult to produce. The clay-water interaction can cause significant swelling and fines migration in the shale formation, both of which can significantly impair the overall hydrocarbon recovery from shale. Geomaterial micromodels, developed by functionalizing traditional glass or PDMS surface with geomaterials (e.g., calcite, quartz, clay) can represent the physico-chemical properties of the natural porous media and have been used during the last few years to understand and evaluate the solid-fluid physicochemical interactions. This study focuses on developing a clay-coated geomaterial surface and investigates the effect of base fluid's salinity on clay adsorption to the glass surface. Glass capillary tubes and straight channel borosilicate glass micromodels are coated with Illite clay minerals to represent the pore-scale clay chemistry of Caney Shale, a Mississippian unconventional play in Southern Oklahoma, USA. 10 wt.% of Illite clay slurries made with brines of four different salinities are used to coat the glass-capillary tubes to understand the effect of salinity in clay adsorption on the glass surface and overall coating quality. To achieve a stable coating and evaluate the impact of heat treatment on coating's stability, straight channel glass flow cells coated with Illite clay are heat-treated at low (25 °C) and high temperature (125 °C). Dynamic flooding tests were carried out with brines on the coated surface to evaluate the stability of the coating. The experiments' outcome indicated a strong relationship between the brine's salinity and the adsorption of clay particles on the glass surface. An increase in brine concentration resulted in improved adsorption of clay particles on the glass surface. Experiments involving heat treating the glass surface following the coating demonstrated significant improvement in the stability of the coating.

02 PETROLEUM↗
DOE OSTI2022

A Large Eddy Simulation Study of Flow Turbulence, Alumina Transport, and Bath Temperature Evolution in Conventional Aluminum-Smelting Cell Using OpenFOAM

In this study, a Large Eddy Simulation (LES) of the aluminum-smelting process is performed using OpenFOAM. To understand the coupled behavior of heat transfer, mass transfer, and flow of the smelting process, a multi-physics computational fluid dynamics (CFD) model based on the Eulerian–Eulerian multi-fluid approach is adopted. The model accounts for CO 2 bubble and magnetohydrodynamics (MHD)-driven flow, along with alumina dissolution, transport, and bath temperature evolution. The simulation predictions show small-scale turbulent vortical structures in the anode–cathode space caused by combined effect of MHD and CO 2 bubble-bath interactions and relatively large-scale asymmetric vortices in the inter-anode space caused by the CO 2 bubble-bath interactions. The vortex formation at the edges of the anodes evidently aids in transporting alumina from the central channel to the bottom of the anodes and prevents accumulation of gas bubbles in the periphery of the anode bottom. Symmetric bath cold spots are observed in the vicinity of the feeder. Cold spots are also observed in the anode–cathode distance space below the anode bottom due to the transport of undissolved solid to this region by the flow. The findings from the work are useful in developing and designing alumina-feeding strategy leading to reduced anode effects and smooth operation of the cell. The work also highlights the important flow structures in conventional aluminum-smelting cell.

36 MATERIALS SCIENCE↗
DOE OSTI2023

Cast or Additively Manufactured Coils with End Turn Enhanced Heat Transfer Surfaces for Spray or Jet Cooling

Cast or additively manufactured coils present a new opportunity for creativity in thermal management of electric machines. Improvements to the heat transfer of spray or jet cooling of coil end turns through the incorporation of pins or enhanced heat transfer surfaces in the cast end turn surfaces is explored. The thermal response of cast copper half-turns is measured for a range of spray/jet volumetric flow rates and ohmic loss heat fluxes. A significant reduction, ~30%, in the steady state temperature and increased spray cooling heat transfer coefficients was experimentally measured when the pins or enhanced heat transfer surfaces are incorporated.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Brine Availability Test in Salt (BATS) FY24 Update

This report summarizes fiscal year 2024 (FY24) activities centered around a series of field tests in bedded salt at the Waste Isolation Pilot Plant (WIPP) funded by the Office of Spent Fuel and Waste Science and Technology in the Spent Fuel and Waste Disposition (SFWD) program of the US Department of Energy’s Office of Nuclear Energy (DOE-NE). High-level Purpose of Experiments: The Brine Availability Test in Salt (BATS) field tests are revealing both brine occurrence (i.e., where, and how much) and brine migration (i.e., how easily it moves) in the excavation damaged zone (EDZ). This understanding is foundational to develop a safety case for a future heat-generating waste repository in salt, and to starting up a generic repository program in salt to buy down risk. BATS seeks to predict how much brine can flow into both ambient and heated excavations (e.g., boreholes or rooms) in salt. This work is educating and empowering new repository scientists on two fronts: “design and execution of field tests” and “prediction and modeling of coupled processes.” DOE-NE capabilities in salt have grown and been tested through international modeling and benchmarking exercises (e.g., DECOVALEX, RANGERS, KOMPASS, and MEASURES; see Mills et al., 2024). The hands-on expertise we are building is a necessary step towards large-scale disposal demonstrations and eventual implementation.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2024

Capillary-Enhanced Two-Phase Micro-Cooler Using Copper-Inverse-Opal Wick with Silicon Microchannel Manifold for High-Heat-Flux Cooling Application

In this work, we demonstrate a two-phase capillary-fed boiling micro-cooler that consists of a ~ 25-..mu..m-thick copper inverse opal (CIO) porous wicking structure for high-heat-flux boiling and a silicon 3D-manifold for distributed liquid delivery and vapor extraction across a 0.5 cm x 0.5 cm heated area. At low inlet water mass flow rates of 1.5 to 1.9 g(min)-1, the micro-cooler displays nearly two-phase boiling with exit vapor quality ~ 1 and a high critical heat flux (CHF) of 253 to 320 W cm-2 with low superheat of ~ 10 degrees C resulting in a thermal resistance of boiling ~ 0.025 cm2 degrees C W-1 or heat transfer coefficient of 0.4 MW m-2 degrees C-1. For higher flow rates of 5, 10, and 15 g(min)-1, the micro-cooler exhibits a hybrid single-phase and two-phase cooling regime where the contribution of the sensible heat (single-phase) cooling is linearly added to that of the two-phase cooling. For the highest flow rate of 15 g(min)-1, the CHF is increased to ~ 500 W cm-2 resulting in an overall thermal resistance of ~ 0.18 cm2 degrees C W-1. However, the two-phase heat transfer effectiveness, which estimates the utilization level of the inlet mass flow rate for two-phase boiling, is reduced to ~ 0.11. To achieve the best cooling system performances, the micro-cooler must operate entirely within the two-phase boiling regime (exit vapor quality or two-phase heat transfer effectiveness ~ 1). Ideally, the "coolant" should be delivered near its saturation temperature (~ 100 degrees C for water), which provides significant advantages for the energy-efficient operation of data centers and power electronics. We present detailed analysis with Infrared and high speed camera images at various inlet flow rates and heat fluxes to understand complex heat transfer in the micro-cooler. Furthermore, a conjugate thermofluidic simulation model, which incorporates the physics of capillary-fed boiling in a porous copper layer, agrees well with the experimental data.

capillary-enhanced boiling↗
DOE OSTI2020

Investigations on the Thermal-hydraulic Behavior of Accident Tolerant Fuel Cladding Materials

Since the 2011 Fukushima accident, significant research has been devoted to developing accident-tolerant fuel (ATF) cladding materials. These investigations have mostly focused on the ability to resist runaway steam oxidation and retain mechanical strength and structural integrity under thermal shocks. However, much remains unknown about the materials’ thermal-hydraulic behavior, particularly under light-water reactor (LWR) operating conditions. Two phenomena that determine safety margins in both normal and off-normal operating conditions - i.e., the critical heat flux (CHF) and Leidenfrost point (LFP) temperature - have not been investigated thoroughly for ATF materials. Surface properties, such as wettability and roughness, are known to influence pool and flow boiling CHF, as well as the LFP temperature. However, little is known about the surface wettability of ATF materials, particularly at LWR pressure and temperature. Little has been done on flow-boiling CHF and quenching heat transfer, especially for droplet quenching. Nonetheless, it is known that CHF in transient conditions, e.g., an exponentially escalating power transient, can be significantly different from that expected in steady-state operation. Very few studies have investigated transient CHF, either on ATF materials or under LWR pressure and temperature. The thorough understanding of transient CHF under prototypical reactor conditions will benefit not only the deployment of ATF but also the upcoming national efforts to study transient ATF behavior in the Transient Reactor Test Facility (TREAT) at Idaho National Laboratory. In summary, as a part of ATF development efforts, there is an urgent need to understand how and how much these materials may affect two-phase heat transfer phenomena in nuclear reactor conditions.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

A Flow Rate Dependent 1D Model for Thermally Stratified Hot-Water Energy Storage

Stratified tank models are used to simulate thermal storage in applications such as residential or commercial hot-water storage tanks, chilled-water storage tanks, and solar thermal systems. The energy efficiency of these applications relates to the system components and the level of stratification maintained during various flow events in the tank. One-dimensional (1D) models are used in building energy simulations because of the short computation time but often do not include flow-rate dependent mixing. The accuracy of 1D models for plug flow, plug flow with axial conduction, and two convection eddy-diffusivity models were compared with experimental data sets for discharging a 50-gal residential tank and recharging the tank with hot water from an external hot-water source. A minimum and maximum relationship for the eddy diffusivity factor were found at Re <2100 and >10,000 for recirculation of hot water to the top of the tank and vertical tubes inletting cold water at the bottom. The root mean square error decreased from >4 °C to near 2 °C when considering flow-based mixing models during heating, while the exponential decay of the eddy diffusion results in a root mean square error reduction of 1 °C for cone-shaped diffusers that begin to relaminarize flow at the inlet.

1D flow model↗
DOE OSTI2021

Scalable and Resilient Etched Metallic Micro- and Nanostructured Surfaces for Enhanced Flow Boiling

Flow boiling and evaporation in tubes and channels occur in a wide variety of energy systems, such as refrigeration, air conditioning, power generation, electronics cooling, distillation, and purification. In this work, we demonstrate remarkably increased heat transfer coefficients of 270% during refrigerant flow boiling in scalable microstructured (~40 µm), industrial-scale (~1 m long) aluminum (Al) tubes, when compared to smooth unstructured Al tubes. To achieve scalable nanomanufacturing, we create highly conformal and durable structured surfaces by relying on hydrochloric acid Al etching. Flow boiling tests were conducted in 6.35 mm diameter Al tubes using R134a refrigerant as the working fluid. To benchmark our approach and to elucidate the effect of the structure length scale, we also fabricated ultrascalable boehmite (AlO(OH)) nanostructured (~300 nm) Al tubes, showing that etched microscale features are necessary and key to enhancement. Durability tests conducted using a 28 day long continual flow boiling experiment demonstrated negligible degradation of the etched surfaces. The scalable and cost-effective techniques used to create these durable, etched-Al microstructures may significantly reduce manufacturing cost when contrasted with current enhancement approaches such as extrusion, drawing, and welding.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Threshold Heat-Flux Reduction by Near-Resonant Energy Transfer

Near-resonant energy transfer to large-scale stable modes is shown to reduce transport above the linear critical gradient, contributing to the onset of transport at higher gradients. This is demonstrated for a threshold fluid theory of ion temperature gradient turbulence based on zonal-flow-catalyzed transfer. Furthermore, the heat flux is suppressed above the critical gradient by resonance in the triplet correlation time, a condition enforced by the wave numbers of the interaction of the unstable mode, zonal flow, and stable mode.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Machine learning-based optimization of air-cooled heat sinks

Machine learning-based models using Artificial Neural Network (ANN) and greedy search algorithm are used to optimize air-cooled parallel plate-finned heat sinks (PPFHSs) subjected to laminar flow over an extensive range of design parameters. Here, the thermal and hydraulic performances of PPFHSs are represented by heat transfer coefficient (h) and pressure drop (ΔP), respectively. Optimization objectives for PPFHS designs can vary from industry to industry depending on their design priorities. The present study proposes a novel and generalized optimization method that defines practical optimization objectives and provides an accurate optimization process to design effective PPFHSs for a wide range of industrial applications with different design requirements. Three optimization objectives are presented in this study: (i) the largest h PΔ, (ii) the largest h within a specified maximum allowed flow rate, and (iii) the lowest weight that maximizes h for operation within the maximum allowed flow rate. While the shortcoming of the first objective is demonstrated, the other two objectives are found to be suitable for designing effective heat sinks (HSs) across different applications. Results suggest a promising trend from the third objective to develop HSs with ~ 37-68% lower weight, 80-85% reduced ΔP, and negligible penalty in h compared with optimized HSs obtained from the second objective. However, since the third objective leads to HSs with thinner fins, structural analysis should be performed to ensure reliable operation of the HSs.

42 ENGINEERING↗
DOE OSTI2020

Development of a Reference Model for Molten-Salt-Cooled Pebble-Bed Reactor Using SAM

To support the development and utilization of the SAM code for fluoride-salt-cooled high-temperature pebble-bed reactor (PB-FHR) safety analysis and licensing, an effort was devoted to developing reference models for PB-FHR primary loop and the reactor cavity cooling system (RCCS). A reference standard problem of a prototypical reactor design is foundational to NRC and industry to verify the adequacy of computer codes and evaluation models for a specific reactor type. The SAM code was enhanced for the reference PB-FHR model development, including a 1D-3D flow coupling scheme and conjugate heat transfer between porous media and solid structures. The reference FHR primary loop model was developed based on the UC Berkeley Mk1 FHR design with additional design features from the Kairos Power’s KP-FHR core. The PB-FHR core is modeled by a two-dimensional porous medium while the rest of the primary loop is represented by a SAM one-dimensional model. A SAM one-dimensional primary loop model was also developed for comparison using a single channel approach for the reactor core. Furthermore, the water-based NSTF cavity was modeled using SAM multi-dimensional flow module, to assist in evaluating SAM capabilities of modeling the emergency heat removal systems relying on RCCS concepts.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2023

Searching for eco-friendly working fluids for an ejector-driven heat pump for domestic water heating

This study searches for refrigerants with low global warming potential (GWP) and zero ozone depletion potential (ODP) for an ejector heat pump water heater (EHPWH). Several criteria are set, and R1336mzz(Z), R601a, R1233zd(E), R1224yd(Z), R1234ze(Z), and R600a are shortlisted. A theoretical model is built to study the performance of EHPWH and the corresponding ejector design at different operating conditions. For the same ejector design, a refrigerant with a high specific heat ratio produces a high entrainment ratio and heating COP. This is because the expansion wave angle in the ejector is small for refrigerants with a high specific heat ratio, allowing more mass flow rate to be entrained. A higher entrainment ratio does not necessarily correlate to a high COP because the saturation curve of the tested refrigerants is not the same. Results show that the heating COP of R601a is the highest, but it is extremely flammable. R1224yd(Z) and R1234ze(Z) are the most candidates for EHPWH when the trade-off between the COP and safety criteria is considered. The results presented in this work could help building an EHPWH using eco-friendly refrigerants.

Mohammed, Ramy H.↗
DOE OSTI2023

Data-Driven RANS Turbulence Closures for Forced Convection Flow in Reactor Downcomer Geometry

Recent progress in data-driven turbulence modeling has shown its potential to enhance or replace traditional equation-based Reynolds-averaged Navier-Stokes (RANS) turbulence models. Here, this work utilizes invariant neural network (NN) architectures to model Reynolds stresses and turbulent heat fluxes in forced convection flows (when the models can be decoupled). As the considered flow is statistically one dimensional, the invariant NN architecture for the Reynolds stress model reduces to the linear eddy viscosity model. To develop the data-driven models, direct numerical and RANS simulations in vertical planar channel geometry mimicking a part of the reactor downcomer are performed. Different conditions and fluids relevant to advanced reactors (sodium, lead, unitary-Prandtl-number fluid, and molten salt) constitute the training database. The models enabled accurate predictions of velocity and temperature, and compared to the baseline k–τ turbulence model with the simple gradient diffusion hypothesis, do not require tuning of the turbulent Prandtl number. The data-driven framework is implemented in the open-source graphics processing unit–accelerated spectral element solver nekRS and has shown the potential for future developments and consideration of more complex mixed convection flows.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

A Simplified Numerical Approach to Characterize the Thermal Response of a Moving Bed Solar Reactor

Abstract Concentrated solar thermochemical storage in the form of a zero-emission fuel is a promising option to produce long-duration energy storage. Solar fuel is produced using a cavity reactor that captures concentrated solar radiation from a solar field of heliostats. In this paper, heat transfer model of a tubular plug-flow reactor designed and manufactured for a solar fuel production is presented. Experimental data collected from a fixed bed tubular reactor testing are used for model comparison. The system consists of an externally heated tube with counter-current flowing gas and moving solid particles as the heated media. The proposed model simulates the dynamic behavior of temperature profiles of the tube wall, gas, and particles under various gas flowrates and residence times. The heat transfer between gas–wall, solid particle–wall, and gas–solid particle is numerically studied. The model results are compared with the results of experiments done using a 4 kW furnace with a 150 mm heating zone surrounding a horizontal alumina tube (reactor) with 50.8 mm outer diameter and thickness of 3.175 mm. Solid fixed particles of magnesium manganese oxide (MgMn2O4) with the size of 1 mm are packed within the length of 250 mm at the center of the tube length. Simulation results are assessed with respect to fixed bed experimental data for four different gas flowrates, namely, 5, 10, 15, and 20 standard liters per minute of air, and furnace temperatures in the range of 200–1200 °C. The simulation results showed good agreement with maximum steady state error that is less than 6% of those obtained from the experiments for all runs. The proposed model can be implemented as a low-order physical model for the control of temperature inside plug-flow reactors for thermochemical energy storage applications.

Engineering↗
DOE OSTI2022

Development of a Subchannel Capability for Liquid-Metal Fast Reactors in Pronghorn

This report details the development and demonstration of an entirely new capability in Pronghorn, namely the ability to model liquid-metal fast reactor (LMFR) flow conditions on the engineering scale. We developed two modeling approaches for LMFR that can be used separately or be combined into a hybrid simulation: (1) a modern subchannel capability called Pronghorn-Subchannel for square and hexagonal lattices, and (2) a porous flow capability for LMFR geometries. The report emphasizes the novel aspects of the developed subchannel capability and the interoperability of the subchannel capability, porous flow capability, and multiphysics tools within the multiphysics object oriented simulation environment (MOOSE). Here we demonstrate the ability to: (1) Accurately model subchannel flow in hexagonal lattices; (2) Couple the subchannel flow model to multidimensional finite-element method (FEM) or finite-volume method (FVM) heat conduction models; (3) Model LMFRs using Pronghorn’s porous media FVM approach; (4) Couple porous flow FVM and subchannel models in a single simulation; (5) Explicitly model inter-wrapper flows along with conjugate heat transfer from the intra-element flow; and (6) Demonstrate the numerical robustness of the subchannel algorithm by simulating intra-element flow recirculation in a high-buoyancy, low-flow fuel element.

97 MATHEMATICS AND COMPUTING↗