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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.
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HIGH-TEMPERATURE PARTICLE FLOW TESTING IN PARALLEL PLATES FOR PARTICLE-TO-SUPERCRITICAL CO2 HEAT EXCHANGER APPLICATIONS.
Abstract not provided.
High-Temperature Particle Flow Testing In Parallel Plates for Particle-to-Supercritical CO2 Heat Exchanger Applications.
Abstract not provided.
Low Flow Acceptance Testing of a 1 MWth Supercritical Carbon Dioxide Primary Heat Exchanger Test System.
Abstract not provided.
Low Flow Acceptance Testing of a 1 MWth Supercritical Carbon Dioxide Primary Heat Exchanger Test System.
Abstract not provided.
Analysis of Laminar Convective Heat Transfer Over Structured Non-Wetting Surfaces
Structured non-wetting surfaces provide alternating no-slip and partial slip boundary conditions to the fluid flow which, in turn, affects the convective heat transfer performance over the surfaces. In this work, an analytical model is developed for the interfacial Nusselt number, the overall Nusselt number and a thermal hydraulic performance factor for fluid flow in a cylinder patterned with structured non-wetting surfaces, for the two cases of uniform wall heat flux and uniform wall temperature. In addition, by considering the stability of the Cassie state of wettability and its transition to the Wenzel state for flow over superhydrophobic surfaces, the present model overcomes certain limitations of the previously reported studies in the literature. Based on the analytical formulations and the stability constraints, the present paper provides optimum design maps for tailoring structured non-wetting surfaces for maximizing convective heat transfer and the combined thermal-hydraulic performance in applications. Use of the design maps on example cases is also discussed. It is shown that the use of structured non-wetting surfaces is most effective for low Reynolds numbers and/or small cylinder radius.
High-Speed and High-Quality Field Welding Repair Based on Advanced Non-Destructive Evaluation and Numerical Modeling
Creep strength-enhanced ferritic (CSEF) steels such as Grade 91 (9Cr-1Mo-V) and Grade 92 (Fe-9Cr-2W-0.5Mo) steels are widely used in the fossil-fuel-fired and nuclear power plants. The weld integrity of these steels is crucial for power plants' safe and reliable operations. Due to harsh service conditions, the steel weld can become susceptible to environmental degradation. Field welding repair is used to restore the degraded weld’s performance where a controlled temper-bead welding technique is commonly used to temper the freshly formed martensite during welding. However, knowledge of weld repairability is limited and experimental trial and error optimization to achieve desired microstructure and joint properties is expensive and time-consuming. Many existing computational models, e.g., finite element models, are limited to solving heat conduction equation and ignoring convective heat transfer due to molten metal flow. These models can result in over-prediction of peak temperatures of weld pool and heat-affected zone (HAZ), which in turn can affect the accuracy of tempering prediction. Moreover, these finite element models require an input of the deposit profiles in advance and thus limits the usability of these models. Here, a molten pool-based, multi-pass multi-layer model has been developed based on computational fluid dynamics (CFD) approach with the Volume of Fluid (VOF) method. The model calculates the bead formation, thereby eliminating the need for pre-determined bead profiles required by finite element models. For computational efficiency, a coordinate system attached to the moving heat source is utilized. A subroutine is developed to convert the temperature profiles in the reference frame stationary to the heat source to that stationary to the workpiece. The converted thermal cycles are then imported into a microstructure model to compute the tempering kinetics and resultant hardness using a Johnson-Mehl-Avrami-Kolmogorov (JMAK), and modified Grange-Baughman parameter. The modeling approach is first developed and validated on single- and multi-pass deposition of stainless steel filler metal onto a SA-533 high strength steel substrate. The models are then applied to a multi-pass V-groove repair weld of Grade 91 steel plate as well as directed energy deposition of Grade 92 steel. Non-destructive characterization of microstructures was performed on Grade 91 and 92 steel welds. Two welding processes, cold metal transfer (CMT) and flux-cored arc welding (FCAW), were investigated for the Grade 91 steel weld samples. For the Grade 92 weld samples, three different heat inputs (low, medium, and high) of gas tungsten arc welding (GTAW) were utilized to replicate traditional field welding processes. The non-destructive evaluation (NDE) method used for this research was immersion ultrasonic testing (UT) using a micro-resolution ultrasonic imaging methodology specifically designed to operate in the through-transmission configuration operating at 20 MHz of frequency. The system used a focused ultrasonic beam spot size diameter between 250-300 μm, and a 6 μm laser vibrometer spot size for detection, to produce highly defined images with longitudinal and mode-converted shear waves. From the micro-resolution ultrasonic C-scan images, three microstructural regions, i.e., weld metal (WM), HAZ, and base metal (BM), were clearly identifiable. Various levels of ultrasonic amplitudes distributed over the three regions were correlated with electron beam backscattered diffraction (EBSD) images using grain size, grain boundaries, and dislocation densities. The results showed that areas with relatively higher ultrasonic amplitude levels were associated with smaller grains and higher dislocation densities, while areas with lower amplitude levels were associated with larger grains and lower dislocation densities. In addition, ultrasonic velocity data obtained across the three different weld microstructural regions of Grade 91 test samples were correlated with optical metallographic images and hardness measurements. The results showed distinctive decreases in ultrasonic velocity and hardness over the HAZ region, where weld failures often occur during service.
New scaling law for turbulent boundary layers with high surface mass transfer
A fundamental understanding of the phenomena occurring in the turbulent boundary layer in the presence of surface blowing is limited, and considerable disagreements persist even in describing primary quantities, such as the boundary layer profile. The theories based on the linear boundary layer equations show that the thickness of the sublayer increases in the presence of surface blowing; therefore, the viscous sublayer and law of the wall modify. In this study, direct numerical simulations (DNS) of turbulent boundary layers with uniform surface mass transfers are carried out in order to scale the velocity profile. Emphasis is placed on moderate to high mass transfer rates, which are relevant to the most common hybrid rockets configuration. DNS data are used to establish a functional law of the wall and a law of wake by means of the relation between the wall shear stress and surface mass transfer. Analysis of the mean kinetic energy budget shows that the magnitude of turbulent kinetic energy increases by surface mass transfer, and the production rate extends significantly in the inner layer as the injection rate increases. DNS data of various surface blowing are used to complete the closure of turbulence kinetic energy equation and develop an eddy viscosity model. The predicted turbulent kinetic energy and eddy viscosity agree with DNS data for moderate to high blowing rates.
Role of poloidal E × B drift in divertor heat transport in DIII‐D
Abstract Simulations for DIII‐D high confinement mode plasmas with the multifluid code UEDGE show a strong role of poloidal E × B drifts on divertor heat transport, challenging the paradigm of conduction‐limited scrape‐off layer (SOL) transport. While simulations with reduced drift magnitude are well aligned with the assumption that electron heat conduction dominates the SOL heat transport, simulations with drifts predict that the poloidal convective E × B heat transport dominates over electron heat conduction in both attached and detached conditions. As poloidal E × B flow propagates across magnetic field lines, poloidal transport with shallow magnetic pitch angles can reach values that are of the same order as would be provided by sonic flows parallel to the field lines. These flows can lead to strong convection‐dominated divertor heat transport, increasing the poloidal volume of radiative power front, consistent with previous measurements at DIII‐D. Due to these convective flows, the Lengyel integral approach, assuming zero convective fraction, is expected to provide a pessimistic estimate for the radiative capability of impurities in the divertor. For the DIII‐D simulations shown here, the Lengyel integral approach underestimates the radiated power by a factor of 6, indicating that, for reliable DIII‐D divertor power exhaust predictions, full two‐dimensional (2D) calculations, including drifts, would be necessary.
Bubble departure and sliding in high-pressure flow boiling of water
Bubble growth, departure and sliding in low-pressure flow boiling has received considerable attention in the past. However, most applications of boiling heat transfer rely on high-pressure flow boiling, for which very little is known, as experimental data are scarce and very difficult to obtain. In this work, we conduct an experiment using high-resolution optical techniques. By combining backlit shadowgraphy and phase-detection imaging, we track bubble shape and physical footprint with high spatial ($6\,\mathrm {\mu }{\rm m}$) and temporal ($33\,\mathrm {\mu }{\rm s}$) resolutions, as well as bubble size and position as bubbles nucleate and slide on top of the heated surface. We show that at pressures above 1 MPa bubbles retain a spherical shape throughout the growth and sliding process. We analytically derive non-dimensional numbers to correlate bubble velocity and liquid velocity throughout the turbulent boundary layer and predict the sliding of bubbles on the surface, solely from physical properties and the bubble growth rate. We also show that these non-dimensional solutions can be leveraged to formulate elementary criteria that predict the effect of pressure and flow rate on bubble departure diameter and growth time.
The Effect of Tropical Pacific Air‐Sea Coupling on the Rainfall Response to Quadrupled CO 2 Forcing
We perform quadrupled CO 2 climate simulations with the Community Earth System Model version 1 (CESM1) to study how air-sea coupling affects the response of tropical rainfall under global warming. We use a hierarchy of ocean models to separate the effects of seasonal mixed-layer entrainment, wind-driven Ekman flows directed perpendicular to the wind, and the near-equator frictional flows directed in the same direction as the wind. We show that the Pacific Ocean's enhanced equatorial warming pattern (EEW) and equatorward ITCZ contraction observed in previous climate simulations emerge when the ocean model includes wind-driven Ekman and frictional flows. Furthermore, the near-equator frictional flow contributes more than half of the heat convergence in the equatorial Pacific Ocean. Finally, we show that although Ekman flow and near-equator frictional flow can both result in EEW, their coupled interactions with the Hadley circulation lead to opposite feedbacks on EEW's strength.
Wettability and CHF limits of Accident-Tolerant nuclear fuel cladding materials in light water reactor conditions
Here, we present the results of experimental investigations aimed at evaluating the thermal–hydraulic performance of chromium-coated zircaloy, i.e., one of the most promising accident tolerant fuel (ATF) cladding material for light water nuclear reactors. Precisely, we investigate the wettability and critical heat flux (CHF) limits of chromium-coated and conventional zircaloy surfaces in prototypical reactor conditions. For both surface types, we measure the contact angle in a vapor-saturated atmosphere from ambient pressure to the operating pressure of pressurized water reactors (PWRs), i.e., ~15 MPa. We measure the ambient-pressure steady-state flow boiling CHF with a spatially uniform heat flux. We measure the high-pressure steady-state flow boiling CHF with a cosine shape heat flux (up to 20 MPa) and with a uniform heat flux (up to 15 MPa), also exploring the effect of CRUD deposits on the chromium-coated surface. Our results reveal that the chromium surface and the bare zircaloy surface have similar wettability and both become super-hydrophilic in PWR conditions, and that there is practically no difference in the steady-state CHF limits, both at low-pressure and high-pressure conditions, also when the chromium-coated surface is covered by a CRUD deposit. However, while the chromium-coating does not improve the CHF compared to the bare zircaloy surface, it improves the post-CHF behavior. The chromium coating prevents the reaction between zircaloy and steam, which results in the formation of a brittle zirconium oxide through the surface of the cladding. We also measure the transient CHF under exponentially escalating heat flux inputs of a nano-smooth and a rough surface mimicking a chromium-coated zircaloy cladding. Interestingly, the results of the transient heat flux tests suggest that the CHF limit for very short periods (i.e., fast transients) is independent of the surface finish, being the same for a rough chromium surface or a nano-smooth surface.
Closed cycle heat engine
Heat engines employing fluid bearing assemblies hermetically sealed with a closed flowpath for a working fluid are generally disclosed. For example, the heat engine includes a rotating drivetrain and a fluid bearing assembly. The rotating drivetrain includes a compressor section, an expander section, and a heat exchanger. The compressor section and expander section together define at least in part a closed flowpath for the flow of a working fluid. The heat exchanger is thermally coupled to the closed flowpath for adding heat to the working fluid. The fluid bearing assembly is configured to utilize the working fluid to support the rotating drivetrain. Further, the fluid bearing assembly is hermetically sealed with the closed flowpath.
Transport Analysis & Optimization in a MW-Scale CO2 Electrolyzer (Final Report)
As Twelve continues to scale up their CO2 electrolyzers, both in the size of a single cell and in the number of cells used in a stack, thermal management becomes a growing concern, since excess heat can affect reaction yield and accelerate degradation. In this project, we aim to computationally explore how the anode flow fields used in Twelve’s CO2 electrolyzers function as heat exchangers. In particular, using a homogenized model of a CO2 electrolyzer, we first estimate the amount of heat generated in a cell. Then, we develop a computational fluid dynamics (CFD) model of the so-called “flow field”, i.e. a flow manifold, based on Twelve’s CAD drawings, to evaluate how these flow fields perform as a heat exchanger for the generated heat. We explore both a single cell and a 3-cell stack operating in parallel, where heat generated in one cell can now be transferred to another cell. We evaluate how performance is affected when environmental heat losses are taken into account. Finally, we leverage topology optimization to explore the types of design features a computational optimization algorithm would suggest to supplement our intuition. Overall, our work aims to provide design recommendations for CO2 electrolyzer flow fields and provides a foundation for future studies of flow field optimization.
Coupling subsurface and above-surface models for optimizing the design of borefields and district heating and cooling systems in the presence of varying water-table depth. In: Proceedings, 46th Workshop on Geothermal Reservoir Engineering
Dynamic energy simulation is important for the design and sizing of district heating and cooling systems with geothermal heat exchange. Current modeling approaches in building and district energy simulation tools typically consider heat conduction through the ground between boreholes, without flow of groundwater. On the other hand, detailed simulation tools for subsurface heat and mass transfer exist, but these fall short in simulating above-surface energy systems. To support the design and operation of such systems, we have developed a coupled model including a software package for building and district energy simulation, and software for detailed heat and mass transfer in the ground. For the first, we use the open-source Modelica Buildings Library, which includes dynamic simulation models for building and district energy and control systems. For the heat and mass transfer in the soil, we use the TOUGH simulator. TOUGH can model heat and multi-phase, multi-component mass transport for a variety of fluid systems, as well as chemical reactions, in fractured porous media. In previous work, we described the coupling of these software packages, including how time-dependent boundary conditions for the borehole walls are synchronized for use in Modelica and TOUGH. We verified that the coupled Modelica/TOUGH code produced consistent results with the original Modelica code for an idealized problem in which heat transfer was purely by conduction in a uniform geologic medium. Here, we examine less idealized problems for which TOUGH’s advanced capabilities for modeling fluid flow are required. The first problem has a shallow vadose zone, and the second problem has a thicker vadose zone with a water-table depth that varies in time, which requires a fine vertical grid discretization for the TOUGH model.
Direct heat exchanger for molten chloride fast reactor
A molten chloride fast reactor (MCFR) includes a plurality of reflectors defining a central core having a core geometric center. A flow channel fluidically connected to the central core. The flow channel includes an outlet flow channel downstream of the central core and an inlet flow channel upstream from the central core. A primary heat exchanger (PHX) disposed outside the central core and between the outlet flow channel and the inlet flow channel. The MCFR also includes a decay heat heat exchanger (DHHX). At least a portion of the DHHX is disposed above the core geometric center, and a fuel salt is configured to circulate at least partially through the outlet flow channel, the DHHX, the PHX, the inlet flow channel, and the central core.
A phase-field method for boiling heat transfer
Here we present a phase field method for heat transfer in two-phase flow with boiling. The vapor/liquid interface evolution is modeled by the Cahn-Hilliard equation. The phase change rate is determined by accounting for the heat conduction balance on either vapor or liquid side of the interfacial area, depending on which side the temperature is assumed to be maintained at the saturation temperature during boiling. The velocity correction scheme proposed by Dong & Shen [27] is extended to solve the Navier-Stokes equations for a non-solenoidal velocity field, and the entropy viscosity method is employed for stabilization. The phase change model is verified by two-dimensional simulations of a vapor bubble growing in super-heated liquid and in film boiling. In both cases, mesh independence of the results is systematically performed. Subsequently, the method is applied to predict the growth of three-dimensional vapor bubble in a rectangular microchannel with boiling flow, achieving good agreement with experimental measurements and available simulation results using the level-set method. The numerical experiments demonstrate that the required mesh resolution for the phase field method is comparable with that of volume of fluid (VoF) and level-set methods.
Autonomous Fracture Conductivity Using Expandable Proppants in Enhanced Geothermal Systems
Summary Early thermal breakthrough in enhanced geothermal systems (EGS) due to the presence of preferential flow channels is a major challenge that endangers efficient and economic heat extraction in such systems. Previous studies mainly focused on adjusting circulation rates of the working fluid, which still leaves significant amounts of untapped heat behind. Currently, there is a lack of technologies for altering flow distribution within the fracture network to achieve uniform heat sweeping in the reservoir. This work presents a novel concept for making proppants to autonomously control fracture conductivity based on the surrounding temperature. Here, proppants with negative thermal expansion coefficients have demonstrated the capability for appropriate fracture conductivity adjustment as a function of temperature to achieve uniform flow across the fracture network. Particle-particle interactions governing such functions are explicitly modeled, and then the Lattice Boltzmann methods (LBM) is used to determine the potential impact of closure stress and temperature changes on the permeability of the proposed proppant packs. Microscale analyses are further used to determine the required material properties to achieve a certain improvement in the permeability of the proppant pack. Our analyses show an enhancement in permeability and the associated fracture conductivity by half of their initial values. Field-scale analysis further confirms the effectiveness of the proposed concept as 31.4% more heat can be extracted from EGS over 50 years of production when the proposed proppants are used. Such novel proppants may effectively delay thermal breakthrough, sweep heat from larger rock volumes, and elongate the life span of the EGS project.