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All sources NASA NTRS DOE OSTI

DOE OSTI2023

Manufacturing and Hydro Testing of a 10 MWe sCO2 Axial Turbine

Abstract Supercritical CO2 (sCO2) power cycles designed for thermodynamic efficiencies above 50% push component designs into pressure and temperature combinations that approach the limits of American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code and ASME Piping Design Codes with Turbine inlet conditions near 250 bar and 715 °C. These design conditions which limit available materials to high nickel alloys are compounded by the high fluid densities of sCO2 at these conditions which result in very compact machinery at the 10 MWe class which are currently being developed for the DOE supercritical transformational electric power (STEP) program. Design of the STEP Turbine is complete with integrated lessons learned from a previous 1 MWth subscale demonstration of a high temperature 10 MWe Turbine designed under the DOE SunShot Program. Fabrication of the STEP Turbine is nearing completion with all housings and pressure containing components in hand. This paper provides a detailed look at design intentions and limitations for the pressurized sections of the main pressure casing and the fabrication of key turbine components. Additional discussion is provided regarding postfabrication inspection and acceptance of the casing for use after issues with casing welds were identified late in the fabrication process.

Engineering↗

DOE OSTI2021

Evaluation of Electrical Resistivity Tomography to Monitor the Transport of Past Releases Beneath Tank Farms

Underground storage tanks at the Hanford Site, in southeastern Washington State, hold radioactive waste generated from four decades of plutonium production. The 149 single-shell tanks and the 28 double-shell tanks have all exceeded their initial design life of approximately 25 years. At least 67 tanks are assumed to have leaked in the past, resulting in radioactive releases into the vadose zone. Gamma ray logging within dry monitoring wells is currently the primary method for tracking the migration of leaked tank waste through the vadose zone. While this approach provides an accurate assessment of radioactive contamination, that information is only provided near (within ~1m) the borehole, leaving most of the vadose zone unmonitored, particularly the important region directly beneath the tank. This report describes a numerical study that investigates the feasibility and performance of time-lapse 3D electrical resistivity tomography (ERT) for long-term monitoring of a hypothetical tank waste location and migration through the vadose zone. ERT is a method of remotely imaging the bulk electrical conductivity (EC) of the subsurface, which is significantly impacted by the presence of conductive solid and liquid tank waste. The release of liquid tank wastes increases subsurface fluid conductivity and saturation over time, creating a target to use time-lapse ERT for long-term monitoring. Although the presence of metallic infrastructure can cause ERT interference, recent advancements in ERT data processing enable the deleterious effects of buried metallic infrastructure (e.g. pipes, wellbore casings, tanks) to be removed to better determine the liquid tank waste migration over time. Three hypothetical realistic scenarios were simulated in the ERT evaluation. The first two scenarios assume the same leak amount and rate (i.e., between 1/1/1951 and 12/31/1951 at the rate of 347 m 3 per year) but different leaky tanks. Scenario 1 assumes leaks under tank B-102, which is located on the edge of the B-tank farm and surrounded by a few metallic infrastructure including cased pipes/wells/tanks. Scenario 2 assumes leaks under tank B-108, which is located near the center of the B-tank farm and surrounded by larger amount of metallic infrastructure than B-102. Scenario 3 assumes the same metallic infrastructure as B-102, with a more recent contaminant leak that was simulated to have occurred between 1/1/2018 and 12/31/2023 at a rate of 1.89 m 3 per year. The leak time in Scenarios 1 and 2 corresponds to a historical overfill event in 1951 and Scenario 3 corresponds to a recent found tank leak in 2019. In each scenario, a “true” bulk EC model vs. time reflecting contaminant migration was generated. ERT data was simulated from these “true” bulk EC models and a time-lapse ERT inversion produced “imaged” bulk EC vs. time. Three electrode configurations in two, four and eight boreholes surrounding the leak tank were used in the ERT simulations in each scenario. These borehole configurations were considered logistically feasible and cost-effective for monitoring. The hypothetical ERT boreholes are assumed to have non-metallic casing. By comparing the “imaged” bulk EC with the “true” bulk EC, it was demonstrated that the three configurations of wells used (two, four, and eight wells) were able to successfully monitor the migration of tank leaks through the vadose zone, with bulk EC resolution increasing with the number of down borehole ERT arrays for all scenarios. Therefore, the use of eight boreholes to perform ERT monitoring beneath the tanks provided the best spatiotemporal information.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2020

Power Generation Cycle with RELAP-7

Balance of plant of a High-Temperature gas-cooled Reactor – Pebble bed Module (HTR-PM) is modeled using RELAP-7. The model includes the primary helium loop where the heat produced by the core is transferred to a helical-coil steam generator and the secondary loop where super-heated steam is fed to a turbine to extract power. The steam is then condensed to subcooled water and pumped back into the steam generator. Results demonstrate that RELAP-7 has the capability to model different regimes encountered in two-phase flow with wall boiling, superheated steam, subcooled liquid and condensation. RELAP-7 also has the capability of modeling different fluids with their own specific models in a very flexible way, without any code change. This also demonstrates the capability of modeling the transfer of fission power into electrical power.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1969

Liquid-metal-piston MHD generator

Magnetohydrodynamic generator uses a slug or piston of liquid potassium as the working fluid. An expanding vapor of the metal is allowed to reciprocate the liquid-metal-piston through a magnetic field and the expansion energy is converted directly into electrical energy.

Palmer, J. P.↗

NASA NTRS1974

Development of coatings to control electroosmosis in zero gravity electrophoresis

A major problem confronting the operation of free fluid electrophoresis in zero gravity is the control of electrokinetic phenomena and, in particular, electroosmosis. Due to the severity of counter flow, as a result of electroosmosis, the electrical potential developed at the surface of shear must be maintained at near, or as close to, zero millivolts as possible. Based upon this investigation, it has been found that the amount of bound water or the degree of hydroxylation plays a major role in the control of this phenomena. Of necessity, factors, such as adhesion, biocompatibility, protein adsorption, and insolubility were considered in this investigation because of the long buffer-coating exposure times required by present space operations. Based upon tests employing microcapillary electrophoresis, it has been found that gamma amino propyl trihydroxysilane produced a coating which provides the lowest potential (minus 3.86 mv) at the surface of shear between the stationary and mobile layers. This coating has been soaked in both borate and saline buffers, up to three months, in a pH range of 6.5 to 10 without deleterious effects or a change in its ability to control electrokinetic effects.

Krupnick, A. C.↗

NASA NTRS1974

Development of coatings to control electroosmosis in zero gravity electrophoresis

Krupnick, A. C.↗

NASA NTRS1982

Space Operations Center System Analysis: Requirements for a Space Operations Center, revision A

The system and program requirements for a space operations center as defined by systems analysis studies are presented as a guide for future study and systems definition. Topics covered include general requirements for safety, maintainability, and reliability, service and habitat modules, the health maintenance facility; logistics modules; the docking tunnel; and subsystem requirements (structures, electrical power, environmental control/life support; extravehicular activity; data management; communications and tracking; docking/berthing; flight control/propulsion; and crew support). Facilities for flight support, construction, satellite and mission servicing, and fluid storage are included as well as general purpose support equipment.

Woodcock, G. R.↗

NASA NTRS1981

Towards a high-temperature solar electric converter

The concept of an ultrahigh-temperature solar electric heat-engine converter is examined in which an alkali plasma would serve as both the high-temperature collector of solar radiation and as the working fluid for a high-temperature working cycle. The working cycle would be a simple magnetohydrodynamic Rankine cycle. Theoretical and experimental results obtained to date are summarized. These include: (1) an experimental confirmation of the theoretical prediction that a plasma temperature of about 2800 K can be reached through heating cesium vapor by sunlight concentrated to approximately 300 W per sq cm; and (2) the establishment of a theoretical model of the complete solar heated plasma magnetohydrodynamic cycle.

Dunning, G. J.↗

NASA NTRS1984

Variable-Conductance Heat-Transfer Module

Working lengths of heat pipes electronically controlled. Rate of heat transfer controlled by electrical heaters shorten effective working lengths of heat pipes. Concept not limited to right circular cylindrical shape. Concept adaptable to terrestrial instruments or processes in which atmospheres or fluids must be cooled and returned to instruments or processes at fixed lower temperatures.

Hewitt, D. R.↗

NASA NTRS1991

Condenser design for AMTEC power conversion

The condenser and the electrodes are the two elements of an alkali metal thermal-to-electric conversion (AMTEC) cell which most greatly affect the energy conversion performance. A condenser is described which accomplishes two critical functions in an AMTEC cell: management of the fluid under microgravity conditions and optimization of conversion efficiency. The first function is achieved via the use of a controlled surface shape, along with drainage grooves and arteries to collect the fluid. Capillary forces manage the fluid in microgravity and dominate hydrostatic effects on the ground so the device is ground-testable. The second function is achieved via a smooth film of highly reflective liquid sodium on the condensing surface, resulting in minimization of parasitic heat losses due to radiation heat transfer. Power conversion efficiencies of 25 percent to 30 percent are estimated with this condenser using present technology for the electrodes.

Crowley, Christopher J.↗

NASA NTRS1949

Heat transfer from high-temperature surfaces to fluids II : correlation of heat-transfer and friction data for air flowing in inconel tube with rounded entrance

A heat transfer investigation, which was an extension of a previously reported NACA investigation, was conducted with air flowing through an electrically heated inconel tube with a rounded entrance,an inside diameter of 0.402 inch, and a length of 24 inches over a range of conditions, which included Reynolds numbers up to 500,000, average surface temperatures up to 2050 degrees R, and heat-flux densities up to 150,000 Btu per hour per square foot. Conventional methods of correlating heat-transfer data wherein properties of the air were evaluated at the average bulk, film, and surface temperatures resulted in reductions of Nusselt number of about 38, 46, and 53 percent, respectively, for an increase in surface temperature from 605 degrees to 2050 degrees R at constant Reynolds number. A modified correlation method in which the properties of air were based on the surface temperature and the Reynolds number was modified by substituting the product of the density at the inside tube wall and the bulk velocity for the conventional mass flow per unit cross-sectional area, resulted in a satisfactory correlation of the data for the extended ranges of conditions investigated.

Lowdermilk, Warren H↗

NASA NTRS2012

NASA Tech Briefs, September 2012

Topics covered include: Beat-to-Beat Blood Pressure Monitor; Measurement Techniques for Clock Jitter; Lightweight, Miniature Inertial Measurement System; Optical Density Analysis of X-Rays Utilizing Calibration Tooling to Estimate Thickness of Parts; Fuel Cell/Electrochemical Cell Voltage Monitor; Anomaly Detection Techniques with Real Test Data from a Spinning Turbine Engine-Like Rotor; Measuring Air Leaks into the Vacuum Space of Large Liquid Hydrogen Tanks; Antenna Calibration and Measurement Equipment; Glass Solder Approach for Robust, Low-Loss, Fiber-to-Waveguide Coupling; Lightweight Metal Matrix Composite Segmented for Manufacturing High-Precision Mirrors; Plasma Treatment to Remove Carbon from Indium UV Filters; Telerobotics Workstation (TRWS) for Deep Space Habitats; Single-Pole Double-Throw MMIC Switches for a Microwave Radiometer; On Shaft Data Acquisition System (OSDAS); ASIC Readout Circuit Architecture for Large Geiger Photodiode Arrays; Flexible Architecture for FPGAs in Embedded Systems; Polyurea-Based Aerogel Monoliths and Composites; Resin-Impregnated Carbon Ablator: A New Ablative Material for Hyperbolic Entry Speeds; Self-Cleaning Particulate Prefilter Media; Modular, Rapid Propellant Loading System/Cryogenic Testbed; Compact, Low-Force, Low-Noise Linear Actuator; Loop Heat Pipe with Thermal Control Valve as a Variable Thermal Link; Process for Measuring Over-Center Distances; Hands-Free Transcranial Color Doppler Probe; Improving Balance Function Using Low Levels of Electrical Stimulation of the Balance Organs; Developing Physiologic Models for Emergency Medical Procedures Under Microgravity; PMA-Linked Fluorescence for Rapid Detection of Viable Bacterial Endospores; Portable Intravenous Fluid Production Device for Ground Use; Adaptation of a Filter Assembly to Assess Microbial Bioburden of Pressurant Within a Propulsion System; Multiplexed Force and Deflection Sensing Shell Membranes for Robotic Manipulators; Whispering Gallery Mode Optomechanical Resonator; Vision-Aided Autonomous Landing and Ingress of Micro Aerial Vehicles; Self-Sealing Wet Chemistry Cell for Field Analysis; General MACOS Interface for Modeling and Analysis for Controlled Optical Systems; Mars Technology Rover with Arm-Mounted Percussive Coring Tool, Microimager, and Sample-Handling Encapsulation Containerization Subsystem; Fault-Tolerant, Real-Time, Multi-Core Computer System; Water Detection Based on Object Reflections; SATPLOT for Analysis of SECCHI Heliospheric Imager Data; Plug-in Plan Tool v3.0.3.1; Frequency Correction for MIRO Chirp Transformation Spectroscopy Spectrum; Nonlinear Estimation Approach to Real-Time Georegistration from Aerial Images; Optimal Force Control of Vibro-Impact Systems for Autonomous Drilling Applications; Low-Cost Telemetry System for Small/Micro Satellites; Operator Interface and Control Software for the Reconfigurable Surface System Tri-ATHLETE; and Algorithms for Determining Physical Responses of Structures Under Load.

Source record↗

DOE OSTI2023

The Thermal Plumbing System of Stromboli Volcano, Aeolian Islands (Italy) Inferred From Electrical Conductivity and Induced Polarization Tomography

Abstract We performed the first 3D island‐scale tomography of the electrical conductivity of Stromboli volcano (Aeolian Islands, Italy) using 2D acquisition lines (37.2 km) and a total of 18,880 measurements and 2,402 unique electrode locations. This 3D data set was inverted using a Gauss‐Newton algorithm, parallel‐processing on an unstructured tetrahedral mesh containing 678,420 finite‐element nodes and 3,580,145 elements to account for the topography of the volcanic island. The tomogram exhibits a conductive body (10 −2 –1.0 S m −1 ) consistent with the location of CO 2 and temperature anomalies observed at the ground surface. It corresponds to the hydrothermal system with high electrical conductivity associated with alteration. In order to confirm this interpretation, a 2.5D large‐scale induced polarization tomography was performed crossing the volcano. The joint interpretation of the conductivity and normalized chargeability is done with a petrophysical model previously tested and verified at both shield‐ and strato‐volcanoes. This model implies that alteration (through the effect of the cation exchange capacity associated with clay minerals and zeolites) plays a strong role in both controlling the electrical conductivity and normalized chargeability at Stromboli volcano. A temperature tomogram, derived from the geoelectrical measurements, is consistent with surface temperature anomalies and the Very Long Period (VLP) seismicity related to the mild‐explosive activity. This survey displays at 600 m a.s.l. a lateral shift in the highest temperature location, also corresponding to the source of VLP seismicity. Structural boundaries have a major role in the hottest hydrothermal fluids rising below the active crater terrace of Stromboli volcano.

58 GEOSCIENCES↗

NASA NTRS1949

Heat Transfer from High-Temperature Surfaces to Fluids III - Correlation of Heat-Transfer Data for Air Flowing in Silicon Carbide Tube with Rounded Entrance, Inside Diameter of 3/4 Inch, and Effective Length of 12 Inches

A heat-transfer investigation was conducted with air flowing through an electrically heated silicon carbide tube with a rounded entrance, an inside diameter of 3/4 inch, and effective heat-transfer length of 12 inches over a range of Reynolds numbers up to 300,000 and a range of average inside-tube-wall temperatures up to 2500 R. The highest corresponding local outside-tube-wall temperature was 3010 R.

Sams, Eldon W.↗

DOE OSTI2021

Oxygen enrichment combustion to reduce fossil energy consumption and emissions in hot rolling steel production

The reheating furnace operation in the hot mill is natural gas- and electricity-intensive. Oxygen enrichment combustion for reheating furnaces has been proposed to curb and replace natural gas use. In this study, heat transfer in steel slabs in the combustion environment of a push-type reheating furnace was simulated using a computational fluid dynamics (CFD) model. Two oxygen enrichment methods that optimized for performance were selected— a medium oxygen enrichment (MOE) case and an oxy-fuel (OF) case. A life cycle analysis (LCA) characterized the energy and emission profiles of an integrated iron and steel manufacturing process using the two oxygen enrichment cases for the hot mill. These conditions were evaluated for energy use and carbon intensity and compared with a baseline case. Results show that with oxygen enrichment, natural gas consumption can decrease by 19.6%–26.8%, total energy consumption (natural gas and electricity) can decrease by 15.1%–20.7% in the hot mill. Emissions of greenhouse gases can decrease by 11.1%–15.2% in the two optimized cases with 14%–27% reductions in regulated criteria pollutants (nitrogen oxides, carbon monoxide, particulate matter, volatile organic compounds, black carbon, organic carbon, and volatile organic carbons). There is a tradeoff between reducing natural gas consumption and increasing electricity demand from a life cycle perspective. Although the OF case resulted in higher energy- and emissions-related benefits, the MOE case showed the more desirable heat flux uniformity, which is key to maintaining product quality. The analysis suggests that oxygen enrichment in the reheating furnace process can have a significant impact on hot mill environmental performance and become a contributing factor in transitioning to low-carbon steel manufacturing.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Demonstration of a multi-channel fluidized bed particle–supercritical carbon dioxide heat exchanger for concentrating solar applications

High-temperature thermal energy storage in oxide particles at temperatures above 600°C can couple concentrated solar energy with high-efficiency thermal power cycles to provide dispatchable solar-driven electricity. Challenges remain in developing cost-effective primary heat exchangers, which require expensive alloys, to extract the high-temperature thermal energy from the particles to power cycle fluids, such as supercritical CO 2 (sCO 2 ) in recuperated Brayton cycles. To explore one pathway for cost-effective, high-temperature particle heat exchangers, the current study demonstrates a shell-and-plate, particle–sCO 2 heat exchanger with narrow- channel fluidized beds coupled with micro-channel sCO 2 flows in the heat exchanger walls. This study evaluates the feasibility of multiple parallel, narrow-channel fluidized beds in shell-and-plate particle–sCO 2 HXs, to achieve high bed-wall heat fluxes at elevated temperatures. A reduced-order model simulates the narrow- channel, fluidized-bed particle–sCO 2 heat exchanger to design the fluidized bed geometry, in terms of depth, height, and number of channels,for a nominal 40-kWth heat exchanger at particle and sCO 2 inlet temperatures up to 600 °C and 400 °C respectively. The resulting shell-and-plate heat exchanger design operates with bubbling fluidization of the downward-flowing oxide particles to enhance bed-wall heat transfer. The heat exchanger core is fabricated with etched sCO 2 micro-channels in thin wall plates that are diffusion bonded to spacer frames to form the shell-and-plate structure with 12 parallel, fluidized bed channels, 10.4 mm deep. The heat exchanger is tested at the National Solar Thermal Test Facility at Sandia National Laboratories with CARBOBEAD HSP particles at design particle flow rates of 0.20 kg s –1 and inlet temperatures up to 525 °C. Results show that fluidization across multiple parallel channel beds can maintain uniform particle inventory with a common freeboard zone above the heat exchanger core. Bubbling fluidization improves particle–wall heat transfer coefficients but also increases axial dispersion of particle thermal energy, which lowers the log- mean temperature difference such that total heat transfer remains relatively constant to within ±10% over a broad range of fluidization gas velocities. The axial dispersion required particle and sCO 2 flow rates to be increased by 25% over model-designed conditions to achieve the targeted 40 kWth, which indicates the importance of incorporating axial dispersion into heat exchanger design models and of deploying bed structures to suppress it. Furthermore, this study demonstrates the feasibility and preferred fluidizing gas conditions for particle heat exchangers for releasing high-temperature thermal energy storage systems.

14 SOLAR ENERGY↗

DOE OSTI2024

Four-dimensional QCD equation of state with multiple chemical potentials

Here, we construct a four-dimensional version of the equation of state (EoS) model neos, neos-4d, as a function of the temperature and chemical potentials of baryon, electric charge, and strangeness for the hot and dense quantum chromodynamics (QCD) matter created in relativistic nuclear collisions. This EoS enables multiple conserved charge current evolution in a relativistic fluid. Input from lattice QCD simulations and a hadron resonance gas model is considered for constructing the equation of state. We investigate its applicability to the relativistic hydrodynamic description of nuclear collisions and present a method for efficient numerical implementation.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

NASA NTRS1977

Compact pulsed laser having improved heat conductance

A highly efficient, compact pulsed laser having high energy to weight and volume ratios is provided. The laser utilizes a cavity reflector that operates as a heat sink and is essentially characterized by having a high heat conductivity, by being a good electrical insulator and by being substantially immune to the deleterious effects of ultra-violet radiation. Manual portability is accomplished by eliminating entirely any need for a conventional circulating fluid cooling system.

Yang, L. C.↗