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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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At least 847 records · Page 47

The Impact of Oxidation-Induced Degradation On Materials Used in Hydrogen-Fired Microturbines

Hydrogen-fueled microturbines are being considered as part of the future green microgrid. However, the use of hydrogen as a fuel presents new challenges for selection and development of suitable high temperature materials for hydrogen combustion. The burning of hydrogen is expected to result in higher operating temperatures and higher than typically observed water vapor contents in exhaust gases versus burning natural gas. In the present work, foil specimens of various Fe- and Ni-based alloys were oxidized in air + 10 % H 2 O and air + 60% H 2 O for up to 5,000 h at 700 °C to simulate the exhaust atmosphere of natural gas and hydrogen-fueled microturbines. Here, the impact of alloy composition and water vapor content on the oxidation/ volatilization induced loss of wall thickness was experimentally evaluated. Enhanced external oxidation and volatilization of Cr 2 O 3 and Ti-doped Cr 2 O 3 scales was observed in air + 60% H 2 O compared to air + 10% H 2 O. No significant impact of the higher water vapor content was observed on Al 2 O 3 scales formed on Fe-based alumina forming alloys. Lifetime modeling was employed to predict the combined effects of water vapor content, gas flow rates, temperature and alloy composition on the oxidation-induced lifetime of the investigated materials.

36 MATERIALS SCIENCE↗

Multiphysics analysis of fuel Fragmentation, Relocation, and dispersal Susceptibility–Part 2: High-Burnup Steady-State operating and fuel performance conditions

The US nuclear industry is pursuing increased cycle lengths and increasing the peak rod-averaged burnup in an effort to increase the economic viability of the US nuclear fleet. Increasing burnup will afford economic viability by enabling utilities to optimize core designs to reduce the number of fresh fuel assemblies per cycle and allow nuclear power plants to operate for a longer period of time. Longer operating periods will also decrease the number of outages experienced by a nuclear power plants and, therefore, offer utilities significant operational savings. However, extending the peak rod-averaged burnup beyond 62 GWd/tU results in operating fuel rods to higher burnup under higher power conditions. This operating regime is expected to result in higher fuel temperatures, fission gas release (FGR), and rod internal pressures (RIPs) that may challenge historical safety basis and affect high-burnup (HBU) experimental testing. In particular, these conditions directly affect fuel fragmentation, relocation, and dispersal (FFRD) susceptibility, so understanding the pretransient operating conditions is critical for developing test plans that evaluate the FFRD and develop strategies to mitigate it. This paper evaluates the operating conditions and fuel performance of HBU (greater than62 GWd/tU rod average) fuel. Additionally, it investigates fuel performance sensitivities and discusses the effect on fuel performance. Here, this work used two codes. Virtual Environment for Reactor Applications (VERA) was used to calculate steady-state power histories, identify HBU operating conditions using 10 different realistic HBU core designs, and down-select rods to a representative subset of fuel rods for subsequent BISON evaluation. The BISON fuel performance code was used to investigate steady-state HBU operating conditions and assess uncertainties associated with FGR and its effect on fuel temperatures and RIPs. The VERA and BISON results will provide direct input for HBU experimental testing and support subsequent TRACE and BISON transient fuel performance analyses.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Effect of Thermal Expansion Coefficient, Viscosity and Melting Range in Simulation of PCM Embedded Heat Exchangers With and Without Fins

Phase change material heat exchangers (PCMHX) have an important role in integrating renewable energy systems. PCMHX can offer high storage density at various temperatures of interest and can be used for grid load shifting purposes. Numerical models enable engineers to estimate PCMHX performance for different design parameters and operating conditions. Modeling phase change phenomena is challenging due to the complex time-dependent nature of the process. The accuracy of models is highly sensitive to PCM thermo-physical properties. Thermal expansion coefficient (β), viscosity (μ) and melting temperature range (MR) of a PCM are important properties, especially when natural convection is not negligible. In PCMHX modeling, using less than accurate values for these properties can have significant impact on the simulation outcomes. These properties and discussions thereof are not readily available in the literature. This paper presents a brief review of the literature and a numerical study investigating the model sensitivity to the above-mentioned properties for PCMHX with and without fins. CFD is used to evaluate the charging (melting) phenomena. The study quantifies the impact of uncertainty in these properties on the melting rate and temperature profile. Constant wall temperature was considered as heat source with no heat loss to ambient. Here, the results show that β and μ has significant effect on the melting rate and evolution of the melting front. For a non-finned domain when comparing results for different published values of β and μ, the deviation in melting time can be up to 12.9% and 57.6% respectively. For high wall temperatures, change in melting range did not impact melting time. But when the wall temperature is reduced, up to 9.8% deviation in melting time is observed.

CFD↗

Hybrid Uses of High-Temperature Reservoir Thermal Energy Storage: Lessons Learned from Previous Projects

One of the critical challenges of the green energy transition is resolving the mismatch between energy generation provided by intermittent renewable energy sources such as solar and wind and the demand for energy. There is a need for large amounts of energy storage over a range of time scales (diurnal to seasonal) to better balance energy supply and demand. Subsurface geologic reservoirs provide the potential for storage of hot water that can be retrieved when needed and used for power generation or direct-use applications, such as district heating. It is important to identify potential issues associated with high-temperature reservoir thermal energy storage (HT-RTES) systems so that they can be mitigated, thus reducing the risks of these systems. This paper reviews past experiences from moderate and high-temperature reservoir thermal energy storage (RTES) projects, along with hot water and steam flood enhanced oil recovery (EOR) operations, to identify technical challenges encountered and evaluate possible ways to address them. Some of the identified technical problems that have impacted system performance include: 1) insufficient site characterization that failed to identify reservoir heterogeneity; 2) scaling resulting from precipitation of minerals having retrograde solubility that form with heating of formation brines; 3) corrosion from low pH or high salinity brines; 4) thermal breakthrough between hot and cold wells due to insufficient spacing. Proper design, characterization, construction, and operational practices can help reduce the risk of technical problems that could lead to reduced performance of these thermal energy storage systems.

energy storage↗

AGR-5/6/7 Irradiation Disassembly and Metrology First Look

The Advanced Gas Reactor (AGR) Fuel Development and Qualification Program was established to perform research and development on tristructural isotropic (TRISO)-coated particle fuel to support deployment of high-temperature gas-cooled reactors (HTGRs), which are graphite-moderated nuclear reactors cooled with helium. This work continues as part of the Advanced Reactor Technologies (ART) TRISO Fuel Program. The overarching program goal is to provide a baseline fuel qualification data set to support licensing, deployment, and operation of HTGRs in the United States. To achieve these goals, the program includes fuel fabrication, irradiations of TRISO fuels and high-temperature materials (e.g., graphite), safety testing and post-irradiation examination (PIE), fuel performance modeling, and fission product transport and source term determination. The ART AGR program has conducted four distinct fuel irradiation experiments in the Advanced Test Reactor (ATR) at Idaho National Laboratory (INL). The first of these irradiation tests, designated AGR-1, began in ATR in December of 2006 and ended in November 2009. This experiment was primarily to act as a shakedown test of the multi-capsule test train design and to provide early data on fuel performance that would be used in fuel fabrication process development. AGR-1 fuel kernels were produced on an engineering scale, but the TRISO coatings and cylindrical fuel compacts were fabricated on a laboratory scale. The AGR-1 PIE was completed and the final report was published in 2015. The second irradiation test, AGR-2, started in ATR in June 2010 and ended in October 2013. The AGR-2 irradiation test was designed to provide fuel performance data for coated particles fabricated on an engineering-scale pilot line using a coater with an internal chamber diameter of 150 mm (6 in.). The final PIE report was published in 2021. AGR-3/4, a single irradiation that combined what were originally conceived as the third and fourth tests, was to support the refinement of fission product transport models and to assess the effects of sweep gas impurities on fuel performance and fission product transport. PIE of the AGR-3/4 experiment is still in progress as of this writing. The subject of this report is AGR-5/6/7, the final qualification test of AGR TRISO fuel made entirely at the engineering scale.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Application of Fe-doped biochar in Cr(VI) removal from washing wastewater and residual Cr(VI) immobilization in contaminated soil

High-content Cr(VI)-contaminated soils are challenging to remediate using a single remediation technique. This study combined soil washing and immobilization to remediate high-content (3440 mg kg -1 ) Cr(VI)-contaminated soil, which investigated the effects of operating time, temperature, and liquid-solid ratio (LSR) on the Cr(VI) removal efficiency of soil washing and evaluated the potential of Fe-doped biochar (FeBC) in soluble Cr(VI) removal from the washing wastewater and residual Cr(VI) immobilization in the washed soil. The Cr(VI) removal efficiency of soil washing increased with the operating time, temperature, and LSR, but still cannot remove Cr(VI) to achieve the safety content (<100 mg kg -1 ). FeBC showed satisfactory potential in both Cr(VI) removal and immobilization from wastewater and soil, in which the main mechanisms involve ion exchange, redox, and coprecipitation. These results demonstrate applying soil washing & immobilization to remediate high-content Cr(VI)-contaminated soil is a promising alternative method.

54 ENVIRONMENTAL SCIENCES↗

Smokeless Chimney using Smoke Opacity as a Combustion Control Parameter (CRADA Final Report)

If operated poorly, wood burning heaters can produce large amounts of particulate matter (PM). Although several instruments are available to monitor PM, most require dilution air and are unable to sample directly from a flue due to the high PM concentrations and temperatures. Opacity sensors can measure color, opacity and smoke density from wood heater stacks. They operate by transmitting a light beam through the emission source and measuring the amount of light intensity lost (opacity) and light not reflected (color). Although opacity sensors are used in several areas, none have been thoroughly evaluated or optimized for measuring smoke from wood heaters.

47 OTHER INSTRUMENTATION↗

Isotope dependence of transport in ST40 hot ion mode plasmas

The ST40 compact, high-field spherical tokamak, operating at 2.1 T and with 1.8 MW of neutral beam heating, achieved central carbon impurity ion temperatures in excess of 10 keV, surpassing their business milestone of 100 M °C (8.6 keV). The high temperature discharges were in the hot ion mode, with $T_i \gg T_e$, and they were achieved in both hydrogen and deuterium plasmas with deuterium neutral beam injection. In order to achieve the high temperature scenarios, careful wall conditioning and scenario optimization was carried out in $H^0 \rightarrow H^+$, $D^0 \rightarrow H^+$, and finally in $D^0 \rightarrow D^+$ plasmas. The TRANSP transport code was employed to study the dependence of confinement and transport on isotopic mass, and the conditions that led to the high measured central ion temperatures in the $D^0 \rightarrow H^+$ and $D^0 \rightarrow D^+$ plasmas. The kinetic profiles input into TRANSP were inferred from line-of-sight and limited radial measurements as well as consistency with a number of other experimental constraints. The TRANSP results first showed that the main species central ion temperature was only 0.5–1 keV lower than the measured carbon impurity temperature, and thus in the high performance plasmas also surpassed the 100 M °C level. TRANSP also showed that while the electron thermal conduction loss was dominant, reductions in central ion transport, and an effective decoupling of the ions from the electrons, led to an increase in central ion temperatures with increasing plasma mass. In fact, the associated confinement times exhibited a strong dependence on the isotopic mass of the thermal plasma. These preliminary results are foundations for dedicated experiments with full kinetic profile measurements on ST40 in the next run campaign.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Maximizing long-term biohydrogen production with Clostridium thermocellum for high solids conversion of lignocellulosic biomass

Biological hydrogen production from lignocellulosic biomass sustainably couples organic waste reduction with renewable energy generation. Efficient conversion is challenged by the structural complexity of lignocellulose and resulting recalcitrance to enzymatic degradation. Clostridium thermocellum natively breaks down biomass with highly effective hemi-/cellulases systems (i.e., cellulosomes) and generates hydrogen in anaerobic cultivation, creating a compelling platform for lignocellulosic biohydrogen production. Achieving commercially viable production rates requires balancing high biomass loading and throughput against uniform mixing conditions required for enzyme dispersion, pH and temperature control, and efficient hydrogen and metabolite removal in continuous operation. To address these barriers to process intensification, we implemented novel reactor and process designs for high-solids lignocellulosic biomass fermentations using the C. thermocellum KJC19-9 strain, genetically engineered for co-utilization of cellulose and hemicellulose sugars (i.e., xylose). Via computational fluid dynamics (CFD) modeling and experimental validation, we achieved a >50% improvement in biohydrogen production with an improved anchor-type impeller morphology, coupled to a threefold reduction in agitation rate. To further reduce rheological constraints and accumulation of toxic metabolites, we then transitioned the process to sequencing fed-batch operation. The resulting process generated 24.87 L H 2 L −1 from 160 g L −1 of deacetylated and mechanically refined (DMR)-pretreated corn stover biomass over 16 days while solubilizing >95% of influent cellulose and hemicellulose, setting a new performance benchmark for continuous production of biohydrogen from lignocellulose.

08 HYDROGEN↗

Combustion, criteria pollutant and soot property assessment of mixing-controlled high-load engine operation with gasoline and diesel

Gasoline compression ignition (GCI) is an emerging technology that can achieve high fuel efficiency and low criteria emissions in diesel engine platforms using gasoline and gasoline-like fuels. While low- and mid-range loads are enabled with low temperature combustion (LTC) approaches, high-loads are more efficient with high temperature combustion (HTC) requiring mixing-controlled combustion (MCC). Lower soot emissions are achieved with gasoline even in high-load MCC than with diesel, but detailed soot properties from gasoline and diesel have been rarely discussed. In order to better understand how high-load operations affect soot properties, in this study gasoline and diesel were tested in a six-cylinder heavy duty engine at 14 bar brake mean effective pressure (BMEP) at similar combustion phasing. Effects of pilot mass ratio and EGR on heat release rates, cylinder temperatures, ignition delay (ID) and combustion duration (CD) were examined, relating with emissions variations with applications of the two fuels. Soot mass and particle number emissions were slightly lower with gasoline than with diesel, resulting in a more favorable NOx-soot trade-off with gasoline like other reports. Contrary to other findings in the literature, gasoline and diesel soot samples presented similar particle distribution shapes, carbon crystalline structures and primary particle sizes, regardless of fuel type and EGR rate. Consequently, the current result proposes that soot particles have undergone similar soot formation and oxidation processes despite reactivity difference and oxygen availability under the examined high-load MCC with similar combustion phases.

02 PETROLEUM↗

The heat transfer coefficient associated with a moving packed bed of silica particles flowing through parallel plates

Concentrating Solar Power (CSP) with thermal energy storage has the potential to be a renewable energy technology with long duration, inexpensive energy storage. Higher temperature operation increases the conversion efficiency and reduces the cost of energy storage. Several emerging CSP designs utilize particles as the solar receiver due to their high temperature stability and low cost. In some designs, the particles are also used as the thermal energy storage (TES) media. In either configuration, an energy transfer is required between the hot particles and the working fluid in the power cycle in a Particle-to-Fluid Heat Exchanger (PtFHX). Understanding the heat transfer between a moving packed bed and a stationary surface is critical to the successful design of a PtFHX. In this paper, a test facility is described in which a moving packed bed of silica sand with particle size 100–600 μm is introduced into the channel formed by two parallel plates, one of which is heated. The effective static thermal conductivity of the particles used for the test are separately measured over the entire range of test temperatures. The inlet and outlet bulk temperatures of the particle flow are measured as are the surface temperatures at several axial locations along the centerline of the plate. The result is the measurement of heat transfer coefficient as a function of temperature for several velocities. The uncertainty of the measurements is presented and the results are compared to model results found in the literature.

14 SOLAR ENERGY↗

Improved Creep and Tensile Properties of a Corrosion Resistant Ni-Based Superalloy Using High Temperature Aging and Nb/Ta Additions

Resistance to creep deformation is essential for cast and wrought Ni-based superalloys in next generation energy systems due to the considerable exposure times required at the operating temperature. Here the amount of precipitate strengthening was increased in variants to Inconel alloy 725 (IN725), a corrosion resistant alloy, to improve its elevated temperature mechanical strength. Additions of Nb or Ta coupled with a high temperature aging (HTA) heat treatment promoted the formation of γ" precipitates and grain boundary phases which led to significant increases in time to failure. The HTA increased the creep life of various alloy formulations as compared to the standard aging heat treatment with a maximum improvement of 371%. The Nb and Ta additions lowered the minimum creep rate (MCR) and had a similar effect on increasing creep life. The positive effect of the additions was more pronounced when coupled with the HTA which employed a higher temperature in the first step of the heat treatment to promote precipitate phase formation. The Ti/Al ratio was used to design alloys with preferential formation of ' or γ" precipitates. Compact morphology precipitates were formed in the alloys with a low Ti/Al ratio. While a low Ti/Al ratio was primarily associated with lower MCRs, the effect on the creep life was less evident than that of the HTA. By using additions of Nb or Ta and a HTA heat treatment, the creep life of IN725 for testing at 973 K (700 °C) and 483 MPa was improved by up to 256%.

36 MATERIALS SCIENCE↗

Performance Validation of a Thermally Integrated 50 kW High Temperature Electrolyzer System

In the proposed project, INL and OxEon seek to improve the value proposition of hydrogen production by integrating reversible fuel cell operations at relatively small scale for distributed energy applications. This goal will be accomplished by converting a 50 kW solid oxide electrolysis cell or SOEC system into a reversible system that operates at 30 kW in electrolysis mode and approximately 10 kW in fuel cell mode. The reversible SOC system will be operated for over 3,000 hours using an improved catalyst in the fuel electrode. Steam for the electrolysis will come from an electric boiler Thermal Energy Distribution System that will be configured to mimic an industrial source of low-grade heat. Thermodynamic analysis will be performed to demonstrate the potential of the system to achieve >85% system efficiency in electrolysis mode. Finally, a technoeconomic analysis will be completed to show potential to produce hydrogen at a cost of $2/kg. The figure at the right indicates a target cost breakdown to achieve that goal.

08 HYDROGEN↗

Measurement of the Natural Convection Heat Transfer in a Magnesium Oxide Electrolytic Cell Concept

The rate of heat transfer by natural convection between the wall and electrolyte of an electrolytic cell that produces magnesium (Mg) from magnesium oxide (MgO) at temperatures near 1000 °C in a molten fluoride salt electrolyte is presented. An experimental model of the cell was developed that enabled measurements of the heat transfer in the absence of electrolysis and at temperatures less than 100 °C over ranges of Rayleigh numbers from 1 × 10 -7 to 7 × 10 -8 and Prandtl numbers from 2 to 6200, ranges that include those anticipated in the operation of the MgO electrolytic cell. The model avoids the substantial experimental challenges associated with the high-temperature, corrosive molten salt to enable a conservative estimate of the heat transfer at a lower cost and greater accuracy than would otherwise be possible. The results are correlated by the expression Nu = 0.412Ra 0.23 Pr 0.15 with Nusselt numbers spanning 30–80. The application of the correlation shows that the heat transfer between the cell wall and the molten fluoride electrolyte at ≈1000 °C is characterized by convection coefficients between 100 and 600 W/m 2 -K and is fast enough to enable heat fluxes up to 10 W/cm 2 without compromising the structural integrity of the steel cell wall.

Engineering↗

Design and development of equi-atomic refractory High Entropy Alloys for use in radiation environments

Development of new structural materials that can withstand the extreme environments of nuclear reactors where the materials are exposed to high dose rate of ~ 30 200 dpa, high temperatures of the order of 500 1000 o C and tens of years of operation is vital for exploiting the “smallest carbon footprint energy source” to its fullest, in order to deal with the energy crisis worldwide. Recently, HEAs have shown superior irradiation properties over conventional alloys like higher resistance to defect formation, lower void swelling, limited irradiation hardening and higher microstructural stability under irradiation, making them potential structural material candidates for reactors. Proper characterization and testing of these materials are essential before they can replace the conventional alloys.

36 MATERIALS SCIENCE↗

Physics-Informed Neural Network Modeling of Li-Ion Batteries: Preprint

Li-ion batteries (LIB) are a promising solution to enable storage of intermittent energy sources due to their high energy density. However, LIBs are known to significantly degrade after about 1000 charge-discharge cycles. LIBs degrade following different degradation modes and at a rate that depends on the operating conditions (external temperature, load). To plan the installation of batteries, appropriate understanding and prediction capabilities of their lifecycle is needed. High-fidelity numerical models of LIBs such as the pseudo-two-dimensional (P2D) model have been shown to accurately represent the charge-discharge-cycle of an LIB given ac- curate choice of the physical parameters. Given the large number of P2D parameters, adjusting them using forward runs is intractable. This work describes the development of a physics-informed neural network (PINN) as a surrogate substitute of the P2D model that captures parameter dependence. The PINN is advantageous as it needs little to no data, and can naturally encode the dependence of every model parameter. Here, a specific training procedure is adopted to efficiently cover parameter space, handle model stiffness and enforce boundary conditions. The trained PINN is validated against numerical solutions of the P2D model, and its applicability to battery degradation modeling is discussed.

battery degradation↗

Quantification of Variation in Combustion Instability Amplitude in a Multi-Nozzle Can Combustor

In this work, we quantify the level of variation in unstable combustion oscillation amplitudes and identify the source of this variation in a multi-nozzle can combustor. At conditions where pollutant emissions are reduced, lean-premixed combustors can undergo thermoacoustic instability when pressure and heat release rate oscillations couple. A commonly used method for suppressing instability is fuel staging, which is a method where fuel is unevenly distributed between nozzles in a multi-nozzle combustor. Our work follows others who have characterized the effect of fuel staging on combustion instability and the mechanisms by which it works during both steady-state and transient operation. One of the outcomes from our previous work was that certain instability operating points display a high level of pressure oscillation amplitude variation. Instead of oscillating at a constant limit-cycle amplitude, the pressure oscillation amplitude varies significantly in time. In this work, we use the concept of permutation entropy to quantify the level of variation in the pressure fluctuation amplitude. We correlate the level of variation with a number of state variables over a range of operating conditions, 291 test cases in all. These state variables include mixture equivalence ratio; transient timescale, amplitude, and direction; hardware temperatures; gas temperatures; and thermoacoustic damping and growth rates. Significant pressure oscillation amplitude variation occurs when the thermoacoustic damping rate is low. The damping and growth rates can be low for a number of reasons, but they are highly correlated with the metal temperature of the centerbody, where the flames are anchored; lower temperatures result in lower damping rates during stable operation and lower growth rates during unstable operation. These results show the importance of the thermal boundary condition on the time-dependent behavior of the thermoacoustic instability.

Westfall, Seth↗

High-Temperature Gas-Cooled Reactors Multiphysics Simulation Demonstration and Code Validation

This study presents a comprehensive benchmarking and verification effort of several thermal-hydraulic and multiphysics capabilities for high-temperature gas-cooled reactor applications. The first part of this effort focuses on the running-in verification of Griffin’s multiphysics capabilities, specifically for simulating the evolution of pebble-bed reactor cores from startup to equilibrium. Since Fiscal Year 2024, improvements and enhancements have been implemented in Griffin, including simplifying the process to specify streamlines and developing the online cross-section generation capability. In the absence of validation data, code-to-code comparisons are conducted with kugelpy, showing good agreement for integral quantities like k-eff predictions and predictions for maximum power density. However, accuracy issues are noted for more detailed quantities like the spatial distribution of fission rate densities which will require further work to address. The second part of this report presents an improved System Analysis Module (SAM) core channel model where the effects of cross flow are considered during the pressurized loss of forced cooling transient, resulting in an improved agreement of the predicted pebble temperature with respect to the predictions from the SAM 2D porous media model. Additionally, the wall channeling effect due to variable porosity at the near wall region of the core is also investigated. Furthermore, to demonstrate Griffin’s online cross-section generation capability, a Multiphysics simulation is performed by coupling Griffin to the SAM core channel model. In the third part of the report, as a part of the Organisation for Economic Co-operation and Development/Nuclear Energy Agency (OECD/NEA) thermal-hydraulic code validation benchmark activity for a high-temperature gas-cooled reactor, the High Temperature Test Facility (HTTF) is investigated first using the NekRS computational fluid dynamics (CFD) code to study the flow mixing phenomenon in the lower plenum of the facility. Then, code-to-code and code-to-data comparisons are performed for Test PG27, which is a pressurized conduction cooldown (PCC) test, using five different codes by six organizations from five countries. The different simulations show good agreements in terms of the general trend but there are differences in some results such as the peak temperatures of different regions and heat removal rate.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗