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DOE OSTI2020

Effect of Evaporation on Vapor Space Flammability in DWPF Process Vessels - 20278

The Savannah River Site (SRS) Defense Waste Processing Facility (DWPF) processes liquid high-level waste (HLW) and encapsulates it in glass within stainless-steel containers suitable for safe, long-term storage and disposal. Radiolytic and chemical decomposition of the liquid waste generates hydrogen and other flammable gases creating a hazard. The rate of flammable gas generation increases by an order of magnitude as temperature increases from sub-boiling to boiling. DWPF controls this hazard in process tanks by ensuring a minimum purge flow through each tank's head space. The minimum purge flow rate is established assuming dry air and neglecting evaporation. However, this study determined that steam from boiling in a representative process tank is sufficient to dilute flammable gases and, thereby, preclude flammability. For sub-boiling, water vapor is an insufficient diluent considering hydrogen's lower flammable limit (LFL) in air. However, the upper and lower flammable limits approach each other in a hydrogen-air-water-vapor environment as the water vapor concentration increases. This effect may preclude flammable conditions if water vapor concentration is about 60 volume percent or higher. A saturated, constant-pressure air-water system would achieve 60 volume percent water vapor at 86 deg. C. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2016

Potential Impact of Cladding Wettability on LWR Transient Progression

The US Department of Energy Office of Nuclear Energy (DOE-NE) Advanced Fuels Campaign (AFC) is working closely with the nuclear industry to develop fuel and cladding candidates with potentially enhanced accident tolerance. This type of fuel is also known as accident tolerant fuel (ATF). Two promising cladding material candidates with potentially enhanced accident tolerance are silicon carbide (SiC) and an iron-chromium-aluminum (FeCrAl) alloy. The FeCrAl alloy features significantly enhanced oxidation resistance versus the Zr-based alloys currently used in state-of-the-art light water reactors (LWRs). Thermal-fluid characteristics are a vital element of a holistic engineering evaluation of ATF concepts. One characteristic related to boiling heat transfer is the critical heat flux (CHF). At CHF, the efficacy of heat transfer rapidly degrades and components can heat up rapidly. CHF is the heat flux at which the departure from nucleate boiling (DNB) occurs in PWRs. DNB is directly relevant to the departure from nuclear boiling ratio (DNBR), which is the ratio between the critical heat flux and the actual heat flux. Surface wettability is an important factor that influences CHF. CHF plays a significant role in determining safety margins during normal operation and also in the progression of potential transient or accident scenarios. Significant changes in CHF properties and boiling heat transfer characteristics will impact the progression of transient and accident events and reactor safety characteristics. Additionally, the behavior of the candidate cladding materials post-CHF impacts reactor safety. A brief description of the relationship between cladding material properties and CHF is provided, followed by an analysis of two hypothetical transient scenarios: a super-prompt reactivity-initiated accident (RIA) and an anticipated transient without scram with instability (ATWS-I). The analysis illustrates the potential impact of cladding material properties on safety margins via direct alteration of calculated CHF values. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2016

Evaluating a Historical Airborne Release Test with Modern Modeling Methods

Safety analysts throughout the U.S. Department of Energy (DOE) complex rely on the data provided in the DOE Handbook, DOE-HDBK-3010, to determine source terms that may be incorporated into the document safety analyses. Most often, analysts simply take the bounding values due to time constraints or simply to bound calculations. This is a safe approach that helps avoid regulatory critique; however, it may not provide results that are meaningful or relevant to the conditions being evaluated. The derivation of the data, such as airborne release fractions (ARFs) and respirable fractions (RFs) in the Handbook often depend on very limited table-top and bench/laboratory experiments, as well as engineering judgment which may not be well substantiated, and may not be representative of the actual situation. One historical dataset included a test where a solid contaminant was sprinkled over a liquid gasoline pool and set on fire (also referred to as Mishima and Schwendiman's test later in this paper). The airborne release was measured over the duration of the burn, but then collected separately for a time after the burning was completed. It can be assumed that the collected contaminant in the latter period corresponds to re-suspended particles, whereas the earlier period collected contaminant includes a combination of directly released as well as early released re-suspended particles. This scenario was recently modeled using SIERRA/Fuego as part of a parametric sensitivity study, however there were some shortcomings of the analysis methods. First, the code at the time lacked a multi-component particle evaporation model, which is necessary to capture the particle size effect of liquid/solid particles that can dynamically evaporate the liquid component. Second, a particle sticking and resuspension model did not exist at the time of the study. Recent model implementation now permits the study be repeated with the improved physical models. In the earlier work, four potential mechanisms were considered to potentially contribute to the release of the particles. These were: 1. Evaporation Induced Entrainment (EIE); 2. Surface Agitation by Wind; 3. Surface Agitation by Boiling; 4. Residue Entrainment (Resuspension). The sensitivity study evaluated mechanism 1 and 3 in the above list. Parameters varied were selected to be a reflection of a practical range of test conditions. The varied parameters included the boiling duration, fuel height, injected mass, particle size, turbulence intensity, and initial particle height. The boiling duration was the most significant parameter. The most significant mechanism was no.3, Surface Agitation by Boiling. This paper reports the implementation of the new multi-component evaporation model and its effect on the findings from the previous effort. The Mishima and Schwendiman test was re-modeled with the new evaporation model, and the results of the re-evaluation are presented. (authors)

07 ISOTOPE AND RADIATION SOURCES↗

DOE OSTI2016

Assessment of a Smoothed Particle Hydrodynamics Method for Thin Film on Textured Surfaces

A large number of previous studies suggest that the behavior of the near-wall liquid micro-layer plays a key role in boiling heat transfer and boiling crisis; see examples. The thin liquid layer interacts with heater surface and 'external' two-phase flow. The net effects of these interactions define the micro-hydrodynamics that leads to dryout. As a result, a good understanding of the thin-layer hydrodynamics is significant for the accurate prediction of CHF. Recently, with the advent of nanotechnology including micro-scale manufacturing, it becomes possible to perform high heat-flux boiling experiments with controlled surface conditions. Although many reports show rich observations about the effects of surface characteristics on CHF, physical mechanisms remain not fully understood. In order to have better understanding of the above phenomena, several computational models are developed, ranging from the lubrication theory to CFD methods. The former models are limited to one-dimensional formulation and unable to deal with the dry-out phenomena. It turns out that CFD methods have a greater potential for the mechanistic study of boiling. Towards the study objective, a particle-based CFD method called Smoothed Particle Hydrodynamics (SPH) is adopted. SPH is a Lagrangian particle method for solving systems of partial differential equations. Originally SPH is proposed for fluid dynamics in the context of astrophysical problems. Because mass and density are introduced during the particle approximation, SPH is also applied in fluid dynamic problems, where mass and density are important parameters to determine, without mass loss (a limitation of interface capturing schemes in mesh-based methods). Besides, geometrically complex and/or dynamic boundaries and interfaces can be handled without undue difficulty in SPH. Currently, most SPH simulations focus on large-scale scenarios (meter scale), like flooding and solitary wave. Also some works have been done with SPH in pore-scale. As for micro- or nano-scale simulation, people usually apply Dissipative Particle Dynamics (DPD) and Molecular Dynamics (MD) for particle-based simulation. Almost no work has been done on micro-scale with SPH, so assessments are needed to investigate the capability of SPH in application of micro-hydrodynamics. The Phenomena Identification and Ranking Table (PIRT) is applied to align application's technical requirements with associated physics and materials, models, simulation code capabilities and verification, validation and uncertainty quantification activities. The figures of merit are determined as: (1) Timing of micro-layer rewetting dry surface; (2) Effects of surface features. The corresponding key phenomena are determined as: (1) Hydrodynamics; (2) Interface Dynamics; (3) Energy; (4) Surface Effect. This study deals with isothermal scenario and no energy term is considered. Based on the current needs, a new SPH package, Micro-SPH, is compiled based on SPHysics with surface tension and wettability built in. Test cases are performed with Micro-SPH to assess the capability of SPH to each phenomenon identified. NEUTRINO with incompressible SPH solver is employed to investigate micro-fluid dynamics on a surface with uniformly distributed cylindrical pillars for application purposes. (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2017

Methodology of Experiment Design for Improving Transient Critical Heat Flux Model Development

One phenomenon that contributes to nuclear fuel and clad failure mechanisms is the departure from nucleate boiling (DNB). Accident scenarios such as reactivity-initiated accidents (RIAs) provide conditions where the frequency of boiling crisis is much more likely to occur and on much shorter time scales than loss of coolant (LOCA) or loss of flow (LOFA) accidents. Here, boiling crisis in the form of DNB is attributed to transient-induced heat flux values that exceed the critical heat flux (CHF). The resulting effects, such as bubble crowding and eventual dryout, can affect flow boiling heat transfer and compromise the structural integrity of nuclear reactor materials. The focus of the work proposed here lies in developing a rigorous process using out-of-pile testing, under simulated RIA conditions, to determine the transient critical heat flux of cladding materials, without contributions from aforementioned radiation-induced effects that have been observed during in-pile experiments. This study provides a road-map for developing and performing experiments that simulate the power profile and energy deposition aspects of transient events, specific to RIAs, on the laboratory scale. The goal of our project is to observe and measure DNB in an annular flow channel around a single heater rod that is operating and nominal thermal hydraulic conditions of a PWR. It is also an aim of these experiments to determine how to quantify the gap between SS and transient CHF cases, based on state-dependent properties of the cladding material type that is being interrogated. Traditionally, CHF is determined as a combination of four factors: hydraulic diameter, system pressure, mass flow, fluid quality. The authors propose that an additional measureable quantity, which is dependent on the structural properties of the cladding material itself, is partly reasonable for the difference between measured and model-developed CHF values. Using a carefully metered approach will allow for several key concepts to be realized: compensation for transient-based effects to current models for CHF; adaptation of current models for different cladding material types, including Gen-IV concept materials; and implementation of a correction factor to account for both power transient-based and radiation-induced effects on the CHF that have not yet been accounted for.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2026

Understanding the high-temperature behavior and corrosion resistance of Cr-Nb coated cladding for BWRs

While Cr-coated Accident Tolerant Fuel has proven successful in Pressurized Water Reactors, its dissolution in high dissolved oxygen Boiling Water Reactor environments represents a major technological barrier. Here, this study presents a comprehensive evaluation of novel Cr-Nb alloys as a coating breakthrough solution for Accident Tolerant Fuel cladding in Boiling Water Reactors. We systematically investigated Physical Vapor Deposited Cr-Nb coatings with 13% and 24 at% Nb content on commercial Zr-based cladding through rigorous testing under both normal and accident conditions. Our results demonstrate Cr-Nb coatings remained completely intact during extended Boiling Water Reactor autoclave testing, while pure Cr coatings failed catastrophically due to oxide dissolution. Under Loss-of-Coolant Accident conditions at 1100°C, Cr-Nb coatings maintained protective capability for 45 min. At 800°C, the alloy coatings matched pure Cr's excellent corrosion resistance. Despite microstructural changes during prolonged high-temperature exposure, no coating delamination occurred, ensuring continued protection of the underlying Zr substrate. These findings establish Cr-Nb coatings as a viable Accident Tolerant Fuel solution for Boiling Water Reactors.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2015

Mechanisms of material removal and mass transport in focused ion beam nanopore formation

Despite the widespread use of focused ion beam (FIB) processing as a material removal method for applications ranging from electron microscope sample preparation to nanopore processing for DNA sequencing, the basic material removal mechanisms of FIB processing are not well understood. We present the first complete atomistic simulation of high-flux FIB using large-scale parallel molecular dynamics (MD) simulations of nanopore fabrication in freestanding thin films. We focus on the root mechanisms of material removal and rearrangement and describe the role of explosive boiling in forming nanopores. FIB nanopore fabrication is typically understood to occur via sputter erosion. This can be shown to be the case in low flux systems, where individual ion impacts are sufficiently separated in time that they may be considered as independent events. But our detailed MD simulations show that in high flux FIB processing, above a threshold level at which thermal effects become significant, the primary mechanism of material removal changes to a significantly accelerated, thermally dominated process. Under these conditions, the target is heated by the ion beam faster than heat is conducted away by the material, leading quickly to melting, and then continued heating to nearly the material critical temperature. This leads to explosive boiling of the target material with spontaneous bubble formation and coalescence. Mass is rapidly rearranged at the atomistic scale, and material removal occurs orders of magnitude faster than would occur by simple sputtering. While the phenomenology is demonstrated computationally in silicon, it can be expected to occur at lower beam fluxes in other cases where thermal conduction is suppressed due to material properties, geometry, or ambient thermal conditions.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2016

Investigation of HCl-based surface treatment for GaN devices

Surface treatments of GaN in HCl-based solutions are studied by X-ray photoelectron spectroscopy (XPS) and electrical characterization of fabricated GaN surfaces. A dilute-HCl treatment (HCl:H{sub 2}O=1:1) at room temperature and a boiled-HCl treatment (undiluted HCl) at 108°C are made on high-temperature annealed n-GaN. From the XPS study, removal of surface oxide by the dilute-HCl treatment was found, and more thoroughly oxide-removal was confirmed in the boiled-HCl treatment. Effect of the surface treatment on electrical characteristics on AlGaN/GaN transistor is also studied by applying treatment processes prior to the surface SiN deposition. Increase of drain current is found in boiled-HCl treated samples. The results suggest that the boiled-HCl treatment is effective for GaN device fabrication.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2019

DNB performance with modified FY19-GEN1 tests [Slides]

GEN1 boiling model is developed to assess the DNB prediction performance for ”high pressure” flow test, showing “consistent under-prediction”. Based on lessons learned from previous DNB test, a modified boiling model is proposed and tested for high pressure application. For selected tests, modified GEN1 boiling model shows improved DNB performance. Interestingly, DNB performance become poor when the subcooled level is high. More-like PWR condition (High pressure, low subcooled condition), the CASL GEN1 boiling modeling predict the DNB with reasonable accuracy.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2020

Gasoline Engine and Fuels Offering Reduced Fuel Consumption and Emissions: Vehicle Modeling Final Report

The Gasoline Engine and Fuels Offering Reduced Fuel Consumption and Emissions (GEFORCE) project was proposed in response to the U.S. Department of Energy’s Funding Opportunity Announcement 0991 by a team made up of the members of the Coordinating Research Council (CRC) and the research staff at Oak Ridge National Laboratory (ORNL.) The project focused on investigating the potential benefits that might be attained through synergistic use of specific engine technology together with fuels formulated to represent potential directions that high-octane fuels of the future might progress. A stated objective in the DOE FOA was to demonstrate a 25% reduction in petroleum consumption through optimization of the engine technologies together with a suitable fuel. An advanced engine was constructed and used with a matrix of research fuels to investigate potential avenues for efficiency improvement. The engine incorporated technologies expected to become mainstream for boosted engines in the next 10 to 20 years. These included increased compression ratio, a two-stage turbocharger, and cooled external exhaust gas recirculation (EGR). The fuel matrix was designed to investigate impacts from research octane number (RON), volumetric ethanol content, and the final boiling point of the fuel. The engine calibration was optimized for each fuel individually and data collected to enable vehicle system modelling that projected energy consumption, fuel economy, tailpipe CO₂ emissions, and impact on petroleum consumption for an industry-average mid-size sedan. The engine calibration and data collection were carried out at IAV in Michigan and is the subject of a separate report. IAV provided the engine data to Oak Ridge National Laboratory to support the vehicle modelling portion of the project. The vehicle modelling results show the following trends: Ethanol content does have a consistently strong influence on the fuel economy results for all cycles and all fuels. Among the fuels of a nominal RON level, increasing ethanol content consistently lowers fuel economy, with the 30% ethanol fuels always providing the lowest fuel economy for a given RON level. However, in some cases the energy consumption improvement allows the 30% ethanol fuels to match the fuel economy of the ethanol-free fuel P. These observations underscore the importance of both engine efficiency and fuel volumetric energy content on vehicle fuel economy.; There was no consistent trend in the projected energy consumption results for differences in fuel T90 for all fuels and cycles. Fuel economy projections did show a consistent trend, with the higher T90 fuel providing slightly greater fuel economy when compared to the low T90 fuel of the same ethanol content. The observed trends were consistent with differences in the heating value of the fuels.; The 102-RON fuels provided reduced energy consumption and greater fuel economy for the advanced engine on all drive cycles. The engine compression ratio of 11.5 was higher than would typically be used in a turbocharged engine when 92-RON fuel use is expected. Hence, the engine experiences more efficiency degradation from knock avoidance when using the 92-RON fuels. This degradation causes the fuel economy results for the 92-RON fuels to be lower than those for the 102-RON fuels.; Fuels E and F (92-RON, 30% ethanol) are projected to achieve 10% or greater reduction in petroleum consumption, with fuels K (102-RON, 30% ethanol) and O (97 RON, 30% ethanol) achieving greater than a 20% reduction. Fuel L (102-RON, 30% ethanol) achieves greater than 25% reduction, meeting the petroleum reduction target of the project. All of the fuels that achieve 10% or greater reduction in petroleum consumption are 30% ethanol blends.; Increasing final boiling point increased fuel economy at fixed ethanol content when the 102-RON fuels were used. This trend is a result of differences in the volumetric energy content of the fuels and the projected energy consumption values for the fuels. In the case of the 102-RON fuels, increasing final boiling point also resulted in an increase in the energy content of the fuel. There was not a consistent trend between the energy content and final boiling point for the 92-RON fuels at fixed ethanol content.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2022

Report on Year-4 of Water NSTF Matrix Testing: Facility Maintenance and Accident Testing

Under support from the Department of Energy (DOE) and the Office of Advanced Reactor Technologies (ART), a large-scale test facility has been constructed at Argonne National Laboratory to generate NQA-1 qualified validation data for passive decay heat removal systems in advanced reactors. The Natural convection Shutdown heat removal Test Facility (NSTF) reflects key features of a ½ scale, water-based, Reactor Cavity Cooling System (RCCS) and is intended to study the behavior, bound performance, and ultimately guide design decisions for passive decay heat removal systems for advanced reactors. In addition to the experimental activities detailed in this report, a supportive computational modeling effort is on-going which has been demonstrated to significantly strengthen the experimental program while also improving accuracy of the computer models. Together these create a mutually beneficial relationship integral to meeting the overall program objective of examining the heat removal performance of the RCCS concept. This report serves as a summary of maintenance and experimental activities during the program’s fourth year of water-based operation. A planned six-month maintenance period began in August 2021, during which major inspections, repairs, cleaning, and installation of new instrumentation and data acquisition hardware were conducted. Most significantly, two heaters that faulted during Year-3 were repaired, allowing the facility to resume use of the full heated section area and full range of available electric power. The remainder of the year consisted of eight months of test operations, during which the facility logged 211 hours of active heating across one bake-out (following the maintenance period) and seven matrix tests; five classifieds as Accepted per NQA-1, one as Trending, and one as Failed. Testing began by performing two repeat cases to confirm expected facility response and behavior during both single- and two-phase flow conditions, ensuring no changes were introduced during the maintenance period that might have altered the thermal-hydraulic characteristics of the facility. In continuation of the power parametric series initiated in previous years, a high-power test case was then performed examining heat removal performance at a decay heat load equivalent to 2.4 MWt, full-scale, a level exceeding maximum design targets. Additional testing then introduced various blockage scenarios along the network piping, examining the effects of partial and complete blockages of the flow paths on the system behavior and heat removal performance. A study of static boiling tests directed at understanding the geysering two-phase instability was also conducted. The loop was filled only to the bottom of the tank outlet, creating an open loop configuration that prevents any natural circulation flow from occurring, and the heaters were powered on until the facility reached saturation conditions. Following, a series of quasi-steady-state conditions were introduced by adjusting the inventory level in the adiabatic chimney piping at decreasingly lower elevations above the heated region. A strong correlation of geysering characteristics and loop level was observed, with flow and temperature excursions decreasing in intensity, but increasing in frequency, as the fill were reduced to lower elevations along the chimney piping. Once the level fell very low in the chimney, at points near the top of the heated section, the system reached a stable state of continuous boiling without any occurrence of geysering eruptions. A final significant testing accomplishment this year was successful completion of an “accident scenario” test, whose operating conditions were based on a prototypic decay heat curve provided by Framatome and scaled for the NSTF. This test began by establishing steady-state, single-phase “normal operation” conditions, before simulating an accident trip where the availability of active cooling systems was lost. Loop temperatures gradually increased until reaching saturation and subsequent two-phase boiling flow. Over the course of an extended operational period along the defined decay heat curve, steam boil-off caused gradual but continued depletion of liquid inventory until reaching a critically low level causing flow stagnation and cessation of natural circulation heat removal. At this point, after nearly 72 hours of continuous operation, a cold refill was performed to replenish the system inventory and allow the facility to re-establish closed loop natural circulation flow and return to a safe operational state.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1981

Ion beam texturing of heat transfer surfaces

Nucleate boiling heat transfer is examined as a means of energy conservation. Nucleate boiling curves were obtained for ion beam textured copper surfaces, untreated cooper surfaces, copper surfaces which had been polished and surfaces which had been coated with a plasma deposited polymer. Results show that texturing aids heat transfer while polishing has the opposite effect. The polymer coatings did not change nucleate boiling behavior. Aging effects were observed for untreated and for polished surfaces, while no such effects were noticed for textured surfaces. These data suggest that aging may be dependent on surface microgeometry, which is important in nucleate boiling heat transfer.

Agarwal, P. K.↗

NASA NTRS1990

Pool boiler heat transport system for a 25 kWe advanced Stirling conversion system

Experiments to determine alkali metal/enhanced surface combinations that have stable boiling at the temperatures and heat fluxes that occur in the Stirling engine are reported. Two enhanced surfaces and two alkali metal working fluids were evaluated. The enhanced surfaces were an EDM hole covered surface and a sintered-powder-metal porous layer surface. The working fluids tested were potassium and eutectic sodium-potasium alloy (NaK), both with and without undissolved noncondensible gas. Noncondensible gas (He and Xe) was added to the system to provide gas in the nucleation sites, preventing quenching of the sites. The experiments demonstrated the potential of an alkali metal pool boiler heat transport system for use in a solar-powered Stirling engine. The most favorable fluid/surface combination tested was NaK boiling on a -100 +140 mesh 304L stainless steel sintered porous layer with no undissolved noncondensible gas. This combination provided stable, high-performance boiling at the operating temperature of 700 C. Heat fluxes into the system ranged from 10 to 50 W/sq cm. The transition from free convection to nucleate boiling occurred at temperatures near 540 C. Based on these experiments, a pool boiler was designed for a full-scale 25-kWe Stirling system.

Anderson, W. G.↗

NASA NTRS1995

Increasing Precision Of Temperature Sensors Of Liquid H2

Commercial silicon-diode temperature sensors intended for use in boiling or nearly boiling liquid hydrogen at temperatures near 37 degrees R recalibrated to greater precision by method involving careful attention to details of design, operation, and computation. Method based on fundamental electrical and thermodynamic principles and good engineering practice, also applicable to recalibration of other temperature sensors intended for use in other boiling or nearly boiling liquids.

Dempsey, Paula J.↗

NASA NTRS1998

A Report from the Thermal Science Research Center (TSRC)

A vertical flow loop was designed and assembled to determine the local (circumferential and axial) and mean wall temperature distributions for single-phase and two-phase (subcooled and saturated) downward flow in both uniformly-heated and single-side heated vertical channels. Freon-11 was used as the working fluid in order to directly relate and compare the results with a previous experimental campaign which employed this same working fluid. For a given steady-state experiment, the following parameters were held constant: (1) exit pressure, (2) inlet temperature, and (3) mass velocity. For a given configuration of the 2.2 m long cylindrical channel test section, which had a 1.2 m long heated section, the applied heat rate was varied from zero through successive quasi-steady states to a level which corresponded to localized film boiling in the test section. The measurements showed that the boiling curve changes significantly at higher mass velocities with respect to both the circumferential and axial directions. The slope of the boiling curve changes in a non-monotonic fashion with respect to the circumferential directions. The slope of the boiling curve changes in a non-monotonic fashion with respect to the circumferential direction. The measurements point to the existence of a dry-out phenomenon occurring at multiple levels of the applied heat for the single-side heated channel. In comparing the heat transfer for horizontal channel flow with a vertically downward flow, the results show that significantly lower heat transfer occurs in the horizontal flow. However, this trend reverses as both the Reynolds number and the applied heat rate increase. Both the Liu-Winterton and Shah correlations were compared with the experimental data. The Shah correlation predicted the uniformly heated tube data better. When a thermal hydraulic diameter approach was used for the single-side heated case, the data at upstream locations for Z/L less than 0.5 was bounded above by the Liu-Winterton correlation and below by the Shah correlation. At Z/L = 0.5, the Shah correlation bounded the data; and for Z/L greater than 0.5, both correlations overpredicted the data with the Shah correlation being closest to the data. The present results indicate that additional correlational development is needed. In addressing some of the advanced space thermal management objectives concerning accommodating high heat fluxes in non-uniformly heated systems, a large battery of experiments 88 have been completed where local two-dimensional wall temperature variations were measured for both single-phase and two-phase flow in a single-side heated circular tube. As noted above, the results show significant axial and circumferential variations. Accurately accounting for such variations can result in optimized future advanced space, enhanced (high heat flux) thermal management systems.

Boyd, Ronald D.↗

NASA NTRS2003

Self-Propagating Frontal Polymerization in Water at Ambient Pressure

Advances in polymer chemistry have led to the development of monomers and initiation agents that enable propagating free-radical polymerization fronts to exist. These fronts are driven by the exothermicity of the polymerization reaction and the transport of heat from the polymerized product to the reactant monomer/solvent/initiator solution. The thermal energy transported to the reactant solution causes the initiator to decompose, yielding free radicals, which start the free radical polymerization process as discussed in recent reviews. The use of polymerization processes based on propagating fronts has numerous applications. Perhaps the most important of these is that it enables rapid curing of polymers without external heating since the polymerization process itself provides the high temperatures necessary to initiate and sustain polymerization. This process also enables more uniform curing of arbitrarily thick samples since it does not rely on heat transfer from an external source, which will necessarily cause the temperature history of the sample to vary with distance from the surface according to a diffusion-like process. Frontal polymerization also enables filling and sealing of structures having cavities of arbitrary shape without having to externally heat the structure. Water at atmospheric pressure is most convenient solvent to employ and the most important for practical applications (because of the cost and environmental issues associated with DMSO and other solvents). Nevertheless, to our knowledge, steady, self-propagating polymerization fronts have not been reported in water at atmospheric pressure. Currently, polymerization fronts require a high boiling point solvent (either water at high pressures or an alternative solvent such as dimethyl sulfoxide (DMSO) (boiling point 189 C at atmospheric pressure.) Early work on frontal polymerization, employed pressures up to 5000 atm in order to avoid boiling of the monomer/solvent/initiator solution. High boiling point solutions are needed because in order to produce a propagating front, a high front temperature is needed to produce sufficiently rapid decomposition of the free radical initiator and subsequent free radical polymerization and heat release at a rate faster than heat losses remove thermal energy from the system. (While the conduction heat loss rate increases linearly with temperature, the free radical initiator decomposition is a high activation energy process whose rate increases much more rapidly than linearly with temperature, thus as the temperature decreases, the ratio of heat loss to heat generation increases, eventually leading to extinction of the front if the temperature is too low.) In order to obtain atmospheric pressure frontal polymerization in water, it is necessary to identify a monomer/initiator combination that is water soluble and will not extinguish even when the peak temperature (T*) is less than 100 C. In this work acrylic acid (AA) was chosen as the monomer because is it one of the most reactive monomers and can polymerize readily at low temperatures even without initiators. Ammonium persulfate (AP) was chosen as the initiator because it decomposes readily at low temperatures, produces relatively few bubbles and is commercially available. The propagation rates and extinction conditions of the fronts are studied for a range of AA and AP concentrations. Small amounts of fumed silica powder (Cab-o-sil, Cabot Corporation) were added to the solutions to inhibit buoyancy induced convection in the solutions; future studies will investigate the effects of buoyant convection within the solutions.

Olten, Nesrin↗

NASA NTRS2000

Propellant Densification Ground Testing Conducted for Launch Vehicles

The NASA Glenn Research Center at Lewis Field has taken the lead in the development of practical densified cryogenic propellants for launch vehicle applications. The technology of subcooling cryogenic propellants below their normal boiling point to produce a denser fluid is one of the key process technologies necessary to meet the challenge of single-stage-to-orbit and reusable launch vehicles. Densified propellants are critical to lowering launch costs because they enable more propellant to be packed into a given unit volume, thus improving the performance by reducing the overall size and weight of the launch vehicle. This two-pronged research and test program has evolved into (1) conducting tank loading tests using densified liquid hydrogen and (2) developing two large-scale propellant densification systems that will be performance tested next year at Glenn. The propellant-loading test program was undertaken at Glenn in coordination with Lockheed Martin Michoud Space Systems. In this testing, the liquid hydrogen recirculation and densification process was simulated, and the thermal stratification of the densified propellant was recorded throughout the tank. The test article was a flight-weight tank constructed from composite materials similar to those to be used on the X-33 launch vehicle. The tank geometry as designed by Lockheed Martin had two cylindrical lobes with a center septum. Liquid hydrogen flow rate, pressure data, and temperature data plotted over time were collected while the subscale tank was filled with 27 R (15 K) densified liquid hydrogen propellant. This testing has validated mathematical models and demonstrated the readiness of densified propellant technology for near-term use. It marks the first time that such a process has been carried out with a multiple-lobe, flight-similar tank. Glenn researchers have also been working on providing a process and critical test data for the continuous production of densified liquid hydrogen (LH2) and densified liquid oxygen (LO2). Each densification production process uses a high-efficiency, subatmospheric boiling bath heat exchanger to cool the working fluid. A near triple-point hydrogen boiling bath is used to condition and subcool hydrogen to 27 R (15 K), and a nitrogen boiling bath is used to cool the liquid oxygen to 120 R (66.7 K). Multistage centrifugal compressors operating at cryogenic inlet conditions maintain the heat exchanger bath vapor pressure below 1 atm. The LO2 propellant densification unit shown in the photograph has a 30 lb/sec capacity, whereas the LH2 unit was designed to process 8 lb/sec of propellant. Each densification unit will be transported to Glenn's South Forty area after all fabrication work is completed sometime late next year. There the LO2 and LH2 densifier performance tests will be conducted with another larger Lockheed Martin tank designated the Structural Test Article (STA). This liquid oxygen tank is a full-scale, flight-weight, prototype aluminum tank designed for the X-33. It has a capacity of 20,000 gallons of LO2. The tank loading and recirculation testing planned for next year with STA will provide the data necessary for full-scale development of propellant densification technology.

Tomsik, Thomas M.↗

NASA NTRS2003

Multiphase flow and phase change in microgravity: Fundamental research and strategic research for exploration of space

NASA is preparing to undertake science-driven exploration missions. The NASA Exploration Team's vision is a cascade of stepping stones. The stepping-stone will build the technical capabilities needed for each step with multi-use technologies and capabilities. An Agency-wide technology investment and development program is necessary to implement the vision. The NASA Exploration Team has identified a number of areas where significant advances are needed to overcome all engineering and medical barriers to the expansion of human space exploration beyond low-Earth orbit. Closed-loop life support systems and advanced propulsion and power technologies are among the areas requiring significant advances from the current state-of-the-art. Studies conducted by the National Academy of Science's National Research Council and Workshops organized by NASA have shown that multiphase flow and phase change play a crucial role in many of these advanced technology concepts. Lack of understanding of multiphase flow, phase change, and interfacial phenomena in the microgravity environment has been a major hurdle. An understanding of multiphase flow and phase change in microgravity is, therefore, critical to advancing many technologies needed. Recognizing this, the Office of Biological and Physical Research (OBPR) has initiated a strategic research thrust to augment the ongoing fundamental research in fluid physics and transport phenomena discipline with research especially aimed at understanding key multiphase flow related issues in propulsion, power, thermal control, and closed-loop advanced life support systems. A plan for integrated theoretical and experimental research that has the highest probability of providing data, predictive tools, and models needed by the systems developers to incorporate highly promising multiphase-based technologies is currently in preparation. This plan is being developed with inputs from scientific community, NASA mission planners and industry personnel. The fundamental research in multiphase flow and phase change in microgravity is aimed at developing better mechanistic understanding of pool boiling and ascertaining the effects of gravity on heat transfer and the critical heat flux. Space flight experiments conducted in space have shown that nucleate pool boiling can be sustained under certain conditions in the microgravity environment. New space flight experiments are being developed to provide more quantitative information on pool boiling in microgravity. Ground-based investigations are also being conducted to develop mechanistic models for flow and pool boiling. An overview of the research plan and roadmap for the strategic research in multiphase flow and phase change as well as research findings from the ongoing program will be presented.

Singh, Bhim S.↗