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DOE OSTI2021

Vortex Flow and Cavitation in Liquid Injection: A Comparison between High-Fidelity CFD Simulations and Experimental Visualizations on Transparent Nozzle Replicas

Experimental instantaneous shadowgraph visualizations on transparent glass nozzle replicas of high-pressure fuel injectors have been used to validate a novel in-house high-fidelity LES-VOF multiphase solver, to study the evolution of vortex flow and fuel cavitation. Both experiments and simulations capture the formation of an unsteady vapor structure inside the nozzle volume, which is referred to as 'string-cavitation'; strings are found at the core of the recirculation zones. Furthermore, high-fidelity simulations provide a very detailed insight into the vortex generation in the injector nozzle; strings appear within the time scales that are relevant for fast injection events (on the order of 0.1 milliseconds) and, for the problem under consideration, their generation seems mostly related to the flow pattern in the sac. It is also shown that vortexes interact, merge till they disrupt and favor the temporary inception of shear cavitation.

3-phase LES-VOF solver↗

DOE OSTI2026

Reduced-Order CFD Modeling to Support Waste Loading Optimization in Hanford WTP Vitrification

The U.S. DOE Hanford Site stores over 56 million gallons of radioactive liquid tank waste that must be treated and immobilized for long-term disposal The Waste Treatment and Immobilization Plant (WTP) will vitrify this waste by feeding it into Joule-heated melters, where it is incorporated into a stable borosilicate glass Computational fluid dynamics (CFD) simulations of glass melters can provide insight into the maximum achievable waste loading under varying melter operating conditions Fully resolved VOF multiphase simulations were used as the reference model to capture bubble-driven convection in the melter, including bubble formation, rise behavior, and induced glass melt circulation Effective bubble column diameter and rise velocity were extracted from the resolved simulations, compared with empirical correlations, and refit across relevant viscosity and gas flow rate conditions Explicit gas–liquid interface tracking was replaced with a single-phase momentum source term model, enabling faster steady-state CFD simulations while preserving the dominant hydrodynamic effects of bubbling New empirical correlations were developed for effective bubble column diameter and bubble rise velocity by fitting resolved simulation data across expected melter viscosity and gas flow rate ranges, providing improved inputs for the momentum source term model compared with existing literature correlations The momentum source term model reduced fluid-domain mesh size by 89% and achieved an 8.4× computational speedup relative to resolved bubbling simulations The validated momentum source term approach enables prediction of process-relevant heat transfer behavior in the integrated melter model, including heat transfer from the molten glass to the cold cap, plenum, refractory walls, and surrounding structural regions under varying melter operating conditions

12 - MGMT OF RADIOACTIVE AND NON-RADIOACTIVE WASTE↗

DOE OSTI2020

Scaling of two-phase water-steam relative permeability and thermal fluxes in porous media

Two-phase water-steam flow conditions are frequently encountered in many engineering applications, including geothermal reservoirs. Although routine calculations are based on the multiphase Darcy’s law, the role of the topology of the flowing phases at the pore-scale is usually neglected in the estimation of relative permeabilities. Instead, the latter are frequently computed using empirical models like the Corey correlation. In this work, we first apply the model for relative permeabilities based on pore-scale flow regimes developed by Picchi and Battiato (2019), Relative permeability scaling from pore-scale flow regimes, Water Resour. Res. 55, 3215–3233, to scenarios typical of geothermal reservoirs and then extend it by deriving the scaling laws for the transmissibilities and the thermal properties as a function of temperature. First, we discuss the scaling behavior of normalized relative permeabilities in terms of viscosity ratio and capillary number of water-steam systems and, then, we provide a validation of the model against experimental data available in the literature. The model captures well the data trends collected in real 3D porous media. These results suggest that water-steam relative permeabilities follow the same scaling behavior of gas-liquid systems where the non-wetting phase is much less viscous than the wetting phase. Finally, we investigate the impact that relative permeabilities have on heat transfer rates at two-phase flow conditions and the scaling of mass and energy transmissibility and thermal properties of the mixture. An estimation of the exergy carried by the two-phase water-steam mixture is also included.

42 ENGINEERING↗

DOE OSTI2018

Advanced trust region optimization strategies for glass box / black box models

We present an improved trust region filter (TRF) method for optimization of combined glass box/black box systems. Glass box systems refer to models that are easily expressed in an algebraic modeling language, providing cheap and accurate derivative information. By contrast, black box systems may be computationally expensive and derivatives are unavailable. The TRF method, as first introduced in our previous work (Eason and Biegler, AIChE J . 2016; 62:3124–3136), is able to handle hybrid systems containing both glass and black box components, which can frequently arise in chemical engineering, for example, when a multiphase reactor model is included in a flow sheet optimization problem. We discuss several recent modifications in the algorithm such as the sampling region, which maintains the algorithm's global convergence properties without requiring the trust region to shrink to zero in the limit. To benchmark the development of this optimization method, a test set of problems is generated based on modified problems from the CUTEr and COPS sets. The modified algorithm demonstrates improved performance using the test problem set. Finally, the algorithm is implemented within the Pyomo environment and demonstrated on a rigorous process optimization case study for carbon capture. © 2018 American Institute of Chemical Engineers AIChE J , 64: 3934–3943, 2018

Eason, John P.↗

NASA NTRS1993

Progress in Advanced Spray Combustion Code Integration

A multiyear project to assemble a robust, muitiphase spray combustion code is now underway and gradually building up to full speed. The overall effort involves several university and government research teams as well as Rocketdyne. The first part of this paper will give an overview of the respective roles of the different participants involved, the master strategy, the evolutionary milestones, and an assessment of the state-of-the-art of various key components. The second half of this paper will highlight the progress made to date in extending the baseline Navier-Stokes solver to handle multiphase, multispecies, chemically reactive sub- to supersonic flows. The major hurdles to overcome in order to achieve significant speed ups are delineated and the approaches to overcoming them will be discussed.

Liang, Pak-Yan↗

DOE OSTI2023

Gas-Liquid Flow Modeling for Renewable Fuels Production

Aerobic/anaerobic and gas fermentation pathways have emerged as promising new technologies for the generation of renewable fuels/chemicals from biomass derived sugars, and mixtures of greenhouse/energy rich gas streams (CO2/CH4/H2/CO) via microbial action. Example pathways include sugars-to-ethanol conversion, biomethanation (CO2/H2 to CH4), biogas upgrading, CO fermentation and wet-waste conversion. Gas and liquid phase transport, mass-transfer, and mixing physics at large length scales can significantly affect microbial conversion rates, particularly when the microbial reaction requires a narrow set of conditions. These phenomena are difficult to study in small-scale bench-top reactors that are typically well-mixed. Predictive computational fluid dynamics (CFD) based simulations can therefore aid in the scale-up, design and optimization of these reactors. This work presents multiphase Euler-Euler CFD simulations of at-scale (~500 m3) bioreactors. Our mathematical model treats the gas and liquid as interpenetrating phases. This approach reduces the computational complexity of tracking individual gas bubbles that are several orders of magnitude smaller than reactor dimensions. We solve the Reynolds averaged Navier-Stokes (RANS) multiphase equations that account for phase and chemical species transport, interphase mass and momentum transfer and uses a phenomenological model for gas uptake by microbes. We use a customized solver derived from open-source CFD toolbox, OpenFOAM [1], to perform these simulations, which has been validated against small-scale reactors in our previous work [2]. There is currently a knowledge-gap regarding bubble-size distributions when using gas mixtures with vastly different properties, which can have a significant impact overall mass-transfer. For example, hydrogen bubbles are more buoyant compared to other relatively heavier gases (CO2/CH4/CO), resulting in a large distribution of residence times and bubble sizes. This work therefore develops a deeper understanding of bubble dynamics and interphase mass transfer in such heterogenous gas mixtures through well-resolved computational models. We use a population balance model (PBM) for bubble-size-distribution modeling that is validated against small-scale experiments in our solver with an uncertainty quantification study for bubble coalescence and break-up model parameters. Results pertaining to multiple simulations of gas-fermentation reactors are presented where gas mixtures with varying compositions of CO2/CH4/CO/H2 are imposed at the sparger boundaries. The spatio-temporal variations in bubble-size distribution and mass transfer coefficient are analyzed for varying superficial velocities and gas-compositions for varying sizes of bubble-column and airlift reactors. This work will also examine the performance of different reactor designs, viz. bubble column reactor, airlift reactor with an internal draft tube, and a stirred-tank reactor with Rushton impellers. Reactor mass-transfer coefficient, gas hold-up, and dissolved gas distribution are critically analyzed among reactors, and sensitivity studies pertaining to gas flow rates and reactor geometry will be presented. [1] Weller, H., Tabor, G., Jasak, H. and Fureby, C., A tensorial approach to computational continuum mechanics using object-oriented techniques, Computers in physics, 12, 6, 620--631, 1998. [2] Rahimi, M., Sitaraman, H., Humbird, D. and Stickel, J., Computational fluid dynamics study of full-scale aerobic bioreactors: Evaluation of gas-liquid mass transfer, oxygen uptake, and dynamic oxygen distribution, Chemical Engineering Research and Design, 139: 283-295.

BIOMASS FUELS↗

DOE OSTI2016

Released air during vapor and air cavitation

Cavitation today is a very important problem that is solved by means of experimental and mathematical methods. The article deals with the generation of cavitation in convergent divergent nozzle of rectangular cross section. Measurement of pressure, flow rate, temperature, amount of dissolved air in the liquid and visualization of cavitation area using high-speed camera was performed for different flow rates. The measurement results were generalized by dimensionless analysis, which allows easy detection of cavitation in the nozzle. For numerical simulation the multiphase mathematical model of cavitation consisting of water and vapor was created. During verification the disagreement with the measurements for higher flow rates was proved, therefore the model was extended to multiphase mathematical model (water, vapor and air), due to release of dissolved air. For the mathematical modeling the multiphase turbulence RNG k-ε model for low Reynolds number flow with vapor and air cavitation was used. Subsequently the sizes of the cavitation area were verified. In article the inlet pressure and loss coefficient depending on the amount of air added to the mathematical model are evaluated. On the basis of the approach it may be create a methodology to estimate the amount of released air added at the inlet to the modeled area.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2016

Determining Individual Phase Flow Properties in a Quench and Partitioning Steel with In Situ High-Energy X-Ray Diffraction and Multiphase Elasto-Plastic Self-Consistent Method

The micromechanical properties of the constituent phases were characterized for an advanced high strength steels (AHSS) produced by a quenching and partitioning (Q&P) process with in-situ tensile loading under Synchrotron-based high energy X-ray diffraction. The constituent phases present are retained austenite and three martensites (tempered, untempered and freshly formed martensites). For the material investigated, the 200 and 220 lattice strains of the retained austenite phase were calculated by examining the changes of the X-ray diffraction peak positions during deformation. The 200 and 211 lattice strains of the various martensitic phases with similar crystal structures were determined by separating their overlapped diffraction peaks. Apart from tempered and untempered martensite, the diffraction peaks of freshly formed martensite as a result of austenite to martensite transformation can also be able separated due to high initial austenite volume fraction. The phase stresses are first estimated with an empirical relationship through the X-ray diffraction elastic constants (XREC). A multi-phase elasto-plastic self constant model (EPSC) is next used for more accurate determination of the constitutive behaviors of the various phases by comparing the predicted lattice strain distributions and global stress-strain curves with the measured ones. The determined constitutive laws will be used for microstructure-based modeling for sheet formability of the Q&P AHSS steel.

Hu, Xiaohua↗

NASA NTRS2018

Validation of Heat Transfer Correlations in Line Chill-Down Tests of Cryogenic Fluid in SINDA/FLUINT

Line chill-down is an important process in cryogenic tank propellant management, storage, and usage Complex flow dynamics during these processes: boiling heat transfer (film, transition, and nucleate) Understanding boiling phenomena can lead to efficient line chill-down systems that use less propellant, propellant stored, reducing cost for space missions Line Chill-down heat transfer was modelled using SINDA/FLUINT version 5.8 (SF) Multiple chill-down tests were modelled using: heat transfer correlations readily available in SF using HTN/HTC TIES heat transfer empiricisms developed by the University of Florida (UF) based on a series of liquid nitrogen chill-down tests using SF HTU TIES Chill-down tests modelled: liquid nitrogen tests conducted by the University of Florida horizontal flow, upward flow, and downward flow (Reynolds Numbers ranging 850-231,000)liquid hydrogen tests conducted by NASA Glenn Research Center vertical upward flow (Reynolds Number range of 18,400 - 433,000)The flow rate was measured far downstream of the test section, near the system exit. Where to set the flow rate? SF was highly sensitive, and sometime unstable, setting the test flow rate downstream (the outlet) of the test section model and setting the test pressure upstream (the inlet) of the test section model higher flow rate oscillations at the entrance of the model's test section SF was more stable setting the test flow rate upstream (than the downstream flow rate set case)test pressure was used as an inlet (SF plenum) to set the thermodynamic state (temperature and quality) coming into the system setting the appropriate downstream pressure was the unknown. The pressure drops predicted by SF for the downstream set flow rate boundary condition were much smaller than test section measured pressure drops. The multiphase pressure drop correlations used internally in SF may need to be adjusted. Models with an upstream flow rate set assumed a pressure drop that was small

cryogenic modeling↗

DOE OSTI2016

TOGA: A TOUGH code for modeling three-phase, multi-component, and non-isothermal processes involved in CO 2 -based Enhanced Oil Recovery

TOGA is a numerical reservoir simulator for modeling non-isothermal flow and transport of water, CO 2 , multicomponent oil, and related gas components for applications including CO 2 -enhanced oil recovery (CO 2 -EOR) and geologic carbon sequestration in depleted oil and gas reservoirs. TOGA uses an approach based on the Peng-Robinson equation of state (PR-EOS) to calculate the thermophysical properties of the gas and oil phases including the gas/oil components dissolved in the aqueous phase, and uses a mixing model to estimate the thermophysical properties of the aqueous phase. The phase behavior (e.g., occurrence and disappearance of the three phases, gas + oil + aqueous) and the partitioning of non-aqueous components (e.g., CO 2 , CH 4 , and n-oil components) between coexisting phases are modeled using K-values derived from assumptions of equal-fugacity that have been demonstrated to be very accurate as shown by comparison to measured data. Models for saturated (water) vapor pressure and water solubility (in the oil phase) are used to calculate the partitioning of the water (H 2 O) component between the gas and oil phases. All components (e.g., CO 2 , H 2 O, and n hydrocarbon components) are allowed to be present in all phases (aqueous, gaseous, and oil). TOGA uses a multiphase version of Darcy’s Law to model flow and transport through porous media of mixtures with up to three phases over a range of pressures and temperatures appropriate to hydrocarbon recovery and geologic carbon sequestration systems. Transport of the gaseous and dissolved components is by advection and Fickian molecular diffusion. New methods for phase partitioning and thermophysical property modeling in TOGA have been validated against experimental data published in the literature for describing phase partitioning and phase behavior. Flow and transport has been verified by testing against related TOUGH2 EOS modules and CMG. The code has also been validated against a CO 2 -EOR experimental core flood involving flow of three phases and 12 components. Results of simulations of a hypothetical 3D CO 2 -EOR problem involving three phases and multiple components are presented to demonstrate the field-scale capabilities of the new code. This user guide provides instructions for use and sample problems for verification and demonstration.

97 MATHEMATICS AND COMPUTING↗

NASA NTRS1992

In-flight surface-flow measurements on a subsonic transport high-lift flap system

As part of a multiphased program for subsonic transport high-lift flight research, flight tests were conducted on the Transport Systems Research Vehicle (B737-100 aircraft) at the NASA Langley Research Center, to obtain detailed flow characteristics of the high-lift flap system for correlation with computational and wind-tunnel investigations. Pressure distributions, skin friction, and flow-visualization measurements were made on a triple-slotted flap system for a range of flap deflections, chord Reynolds numbers (10 to 21 million), and Mach numbers (0.16 to 0.36). Experimental test results are given for representative flap settings indicating flow separation on the fore-flap element for the largest flap deflection. Comparisons of the in-flight flow measurements were made with predictions from available viscous multielement computational methods modified with simple-sweep theory. Computational results overpredicted the experimentally measured pressures, particularly in the case involving separation of the fore lap, indicating the need for better modeling of confluent boundary layers and three-dimensional sweep effects.

Yip, Long P.↗

DOE OSTI2015

EOS7CA Version 1.0: TOUGH2 Module for Gas Migration in Shallow Subsurface Porous Media Systems

EOS7CA is a TOUGH2 module for mixtures of a non-condensible gas (NCG) and air (with or without a gas tracer), an aqueous phase, and water vapor. The user can select the NCG as being CO2, N2, or CH4. EOS7CA uses a cubic equation of state with a multiphase version of Darcy's Law to model flow and transport of gas and aqueous phase mixtures over a range of pressures and temperatures appropriate to shallow subsurface porous media systems. The limitation to shallow systems arises from the use of Henry's Law for gas solubility which is appropriate for low pressures but begins to over-predict solubility starting at pressures greater than approximately 1 MPa (10 bar). The components modeled in EOS7CA are water, brine, NCG, gas tracer, air, and optional heat.

Oldenburg, CurtisM↗

DOE OSTI2015

EOS7CA Version 1.0: TOUGH2 Module for Gas Migration in Shallow Subsurface Porous Media Systems

EOS7CA is a TOUGH2 module for mixtures of a non-condensible gas (NCG) and air with or without a gas tracer, an aqueous phase, and water vapor. The user can select the NCG as being CO 2 , N 2 , or CH 4 . EOS7CA uses a cubic equation of state with a multiphase version of Darcy’s Law to model flow and transport of gas and aqueous phase mixtures over a range of pressures and temperatures appropriate to shallow subsurface porous media systems. The limitation to shallow systems arises from the use of Henry’s Law for gas solubility which is appropriate for low pressures but begins to over-predict solubility starting at pressures greater than approximately 1 MPa (10 bar). The components modeled in EOS7CA are water, brine, NCG, gas tracer, air, and optional heat. The real gas properties module (ZEVCA) has options for Peng-Robinson, Redlich-Kwong, or Soave-Redlich-Kwong equations of state to calculate gas mixture density, enthalpy departure, and viscosity. Transport of the gaseous and dissolved components is by advection and Fickian molecular diffusion. This user guide provides instructions for use and two sample problems as verification and demonstration of EOS7CA.

03 NATURAL GAS↗

DOE OSTI2015

EOS7CA Version 1.0: TOUGH2 Module for Gas Migration in Shallow Subsurface Porous Media Systems

Oldenburg, Curtis M.↗

DOE OSTI2021

Elliptic flow splittings in the Polyakov–Nambu–Jona-Lasinio transport model

To incorporate the effect of gluons on the evolution dynamics of the quark matter produced in relativistic heavy-ion collisions, we extend the three-flavor Nambu–Jona-Lasinio (NJL) transport model to include the contribution from the Polyakov loops. Imbedding the resulting pNJL partonic transport model in an extended multiphase transport (extended AMPT) model, we then study the elliptic flow splittings between particles and their antiparticles in relativistic heavy-ion collisions at beam energy scan energies. We find that a weak quark vector interaction in the partonic phase is able to describe the elliptic flow splitting between protons and antiprotons in heavy-ion collisions at √sNN=7.7 to 39 GeV. Knowledge of the quark vector interaction is useful for understanding the equation of state of quark matter at large baryon chemical potentials and thus the location of the critical point in the QCD phase diagram.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2015

Aqueous Solution Vessel Thermal Model Development II

The work presented in this report is a continuation of the work described in the May 2015 report, “Aqueous Solution Vessel Thermal Model Development”. This computational fluid dynamics (CFD) model aims to predict the temperature and bubble volume fraction in an aqueous solution of uranium. These values affect the reactivity of the fissile solution, so it is important to be able to calculate them and determine their effects on the reaction. Part A of this report describes some of the parameter comparisons performed on the CFD model using Fluent. Part B describes the coupling of the Fluent model with a Monte-Carlo N-Particle (MCNP) neutron transport model. The fuel tank geometry is the same as it was in the May 2015 report, annular with a thickness-to-height ratio of 0.16. An accelerator-driven neutron source provides the excitation for the reaction, and internal and external water cooling channels remove the heat. The model used in this work incorporates the Eulerian multiphase model with lift, wall lubrication, turbulent dispersion and turbulence interaction. The buoyancy-driven flow is modeled using the Boussinesq approximation, and the flow turbulence is determined using the k-ω Shear-Stress-Transport (SST) model. The dispersed turbulence multiphase model is employed to capture the multiphase turbulence effects.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2017

Numerical comparison of bubbling in a waste glass melter

Radioactive tank waste is scheduled for vitrification at the Hanford Tank Waste Treatment and Immobilization Plant, also known as the Vit Plant, being constructed at the Hanford Site. Testing of the pilot-scale, joule-heated DuraMelter 1200 at the Vitreous State Laboratory has shown that bubbling increases the melt rate, and as a result, melter throughput. Computational fluid dynamics (CFD) models of this pilot-scale waste glass melter were developed to improve our understanding of the processes that occur within the melter to aid in process optimization and troubleshooting of the Vit Plant melters. Unfortunately, model validation is complicated by the difficulty of obtaining suitable experimental data for operational melters attributed to the large-scale, radioactivity and high temperatures at which these melters are operated. This study focuses on confirming the fidelity of the CFD models to accurately reproduce the bubbling behavior. Because of the paucity of experimental data at the resolution required for CFD validation, a code-to-code comparison was used to evaluate two common approaches for simulating flows of immiscible fluids on numerical grids and resolving multiphase interfaces. Here, the volume of fluid and level set methods are used to track the dynamically evolving interfaces between the molten glass and the air bubbles. To aid in the verification of the results of these codes, a comparison of the bubble behavior, growth, and frequency of bubble generation are presented and a grid convergence study is performed for the two approaches. In addition to comparing the numerical results to available experimental data and observations from pilot-scale testing, the results are evaluated in relation to laboratory experiments with bubbles injected into viscous fluids, empirical correlations obtained from the published literature, and the basic laws of fluid dynamics. Furthermore, the results of this work can assist in validating waste glass melter models and provide a better understanding of the flow patterns within the WTP melters.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

NASA NTRS1990

Low energy gamma ray attenuation in multiphase water

A gauging system is proposed to enable monitoring of slush density, solid-liquid interface, and slush level as well as its flow rate. It is based on the principle that the electromagnetic radiation mass attenuation coefficient of a multiphase chemical compound is constant for all relative phase concentrations. Results showing the essential constancy of mass attenuation coefficients for single-phase water vapor, liquid water, ice, and multiphase mixtures of water/ice are described.

Singh, Jag J.↗