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DOE OSTI2023

Realistic fuel spray modeling for gasoline direct injection engine applications

Fuel spray modeling plays a critical role during modern gasoline direct injection (GDI) engine development due to fuel injection’s dominant impact on engine performance and emissions as well as the complex physical processes involved. In engineering three-dimensional (3D) computational fluid dynamics (CFD) simulations, the liquid-phase fuel atomization, evaporation, and mixing are usually modeled with the discrete droplet model (DDM) adopting a Lagrangian approach for multiphase CFD simulations. To this end, general practices heavily depend on the reduced order characterization of the injector nozzle flow. However, such simplified injector modeling may lead to insufficient representations of the complex spray dynamics. To tackle this problem, this study proposes a novel workflow to numerically evaluate GDI sub-cooled and flash-boiling sprays under engine-relevant conditions using a side-mounted GDI injector together with real gasoline fuel properties. The workflow introduces a one-way coupling (OWC) method leveraging high-fidelity nozzle flow simulations to provide realistic boundary conditions to the Lagrangian injector model. The proposed workflow was first verified in a constant volume chamber (CVC) environment and then implemented in a practical GDI engine setup to study spray morphology, fuel-air mixing, and wall-wetting propensity. In addition, detailed comparison was performed between the OWC method and the conventional rate of injection (ROI) routine. In conclusion, quantitative analysis of spray characteristics was conducted to highlight possible source of discrepancies of the conventional ROI method.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2013

Muon Radiography for Non-Destructive, Non-Invasive Assay and Long-Term Monitoring of Nuclear Fuel Debris and Fuel Assemblies.

We propose developing a muon cosmic ray radiography system dedicated to the task of assay and long-term safeguard monitoring of Fukushima fuel debris or fuel assemblies. The system would be non-destructive and non-invasive, using naturally occurring cosmic radiation to assay the entire volume of the fuel debris container. The technique distinguishes between materials and is especially sensitive to measuring the location and amount of heavy elements such as uranium and plutonium. Scope of the feasibility study would encompass a) demonstrating material assay (location and amount) of a regular-shaped depleted uranium object sealed in a debris container, and b) repeating the material assay of debris-proxy materials of irregular shape (corium), sealed in a debris container. Muon radiography of each container would result in a unique “fingerprint” of the contents, useful for long-term safeguards monitoring.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2022

Simultaneous flow of zero-carbon and conventional fuel liquids through Trans-Alaska Pipeline System (Abstract)

The purpose of this CRADA is to address key technical challenges specific to the transport of ammonia, a promising carbon-free fuel and hydrogen-carrier, through crude oil pipelines. Specifically, the project seeks to develop novel technologies for preparing liquid ammonia/ hydrocarbon mixtures for the dual purpose of (i) pipeline transport, and (ii) developing advanced marine fuel blends. By demonstrating compatibility with the Trans-Alaskan Pipeline System (TAPS) ammonia/oil blends may improve access to stranded natural gas and help overcome low-flow issues associated with declining oil productivity. In Alaska, this technology enhances the capabilities of TAPS allowing it to function as a statewide “Hydrogen Highway” for exporting green or blue ammonia. This is strategically important for Alaska which lacks statewide electrical transmission infrastructure but contains vast renewable and fossil resources located in remote regions with few local markets. Nationally, Alaska-sourced green (hydropower) or blue ammonia has the potential to improve reliability of a Pacific Northwest hydrogen storage hub as a hydrogen-carrier by helping to overcome seasonality of green hydrogen produced from solar or wind energy. Globally, this technology project has significant potential to improve the safety and efficacy of ammonia-rich fuel compositions for use in maritime propulsion and other mid-sized engines.

10 SYNTHETIC FUELS↗

DOE OSTI2024

Simultaneous flow of zero-carbon and conventional fuel liquids through Trans-Alaska Pipeline System [Abstract]

08 HYDROGEN↗

DOE OSTI2019

Fuel Diversification to Improve Transportation Resilience in Tampa Bay, FL

The poster summarizes the work to date helping Tampa Bay develop its transportation fuel resilience plan. It will be presented at the TRB resilience workshop. This is the poster version of a publication that has already been published: https://www.nrel.gov/docs/fy19osti/73743.pdf. The only difference is the addition of the last two slides on the poster.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2023

MC Formula Protocol for H35HF Fueling

A publicly available and verified high-flow fueling protocol for H35 medium-duty (MD) and heavy-duty (HD) hydrogen-powered buses and trucks does not exist. This could lead to transit agencies needing to select suppliers for purchase of new fleet vehicles, and to multiple providers responding with incompatible vehicle designs in the future. With the expansion of MD/HD vehicles using 35 MPa storage, there will be a need for publicly accessible H35HF stations, and these will require the use of a standardized prescriptive fueling protocol. The development of a fully tested and validated H35 high-flow (H35HF) MC Formula fueling protocol for MD and HD buses and trucks can provide guidelines to design H35 stations and vehicles, enable other manufacturers and vehicle original equipment manufacturers (OEMs) to enter this space, and ultimately accelerate to popularize the hydrogen market.

ADVANCED PROPULSION SYSTEMS,ENERGY PLANNING, POLIC↗

DOE OSTI2017

Evaluation of the Enhanced LEU Fuel (ELF) Design for Conversion of the Advanced Test Reactor to a Low-Enrichment Fuel Cycle

A conceptual low-enrichment uranium (LEU) fuel design has been developed for the Advanced Test Reactor (ATR) at Idaho National Laboratory. The ATR is currently fueled with a high-enrichment fuel but is slated to be converted to LEU under programs led by the National Nuclear Security Administration of the U.S. Department of Energy. A conceptual LEU fuel design, the Enhanced LEU Fuel (ELF), has been developed assuming power peaking control through the use of variable fuel meat thicknesses and no use of burnable poison. In initial work, this design was shown to satisfy performance requirements for ATR operation. Following these design calculations, a safety analysis process was initiated to demonstrate that the ELF design would successfully meet safety limits for postulated accident conditions. Those calculations, performed using RELAP5 and ATR-SINDA, require physics analysis to provide spatial power distributions and kinetics parameters for various core operations configurations. Finally, this article describes the findings of the physics analysis and provides predictions for the behavior of a LEU-fueled version of ATR, and compares these to calculations of the performance of the current high-enrichment uranium fuel.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2016

Fabrication and Qualification of Small Scale Irradiation Experiments in Support of the Accident Tolerant Fuels Program

The Accident Tolerant Fuels (ATF) program aims to develop next generation Light Water Reactor (LWR) fuels with improved performance, reliability, and safety. The program has developed a roadmap to support the insertion of lead fuel rods (LFRs) or lead fuel assemblies (LFAs) of an accident tolerant fuel into a commercial LWR by the end of FY 2022. In order to achieve this goal, novel fuel compositions and cladding materials are being assembled as drop-in irradiation experiments to allow for prioritization of concepts to further the ATF mission. Development of fabrication methodology and qualification techniques for small-scale irradiation test samples is reported.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

Development and Validation of Physics-Based Sub-Models of High-Pressure Supercritical Fuel Injection at Diesel Conditions Insert

The project sought to develop and validate accurate, physics-based, numerical submodels and implement them in computational fluid dynamics (CFD) software codes to enable accurate predictions of diesel sprays at pressures higher than the current systems. The combined experimental-computational effort has four main objectives: (1) acquire spatially and temporally resolved scalar measurements of fuel-oxidizer mixing in the near field of the fuel jet, (2) develop software modules to calculate thermo-physical properties of diesel surrogates and their mixtures with oxidizer of interest in real-gas operating regime, (3) integrate the real-fluid model into a commercial and an open-source CFD code to simulate fuel-air mixing in high-pressure diesel sprays, and (4) assess the robustness, accuracy, and uncertainty of the integrated CFD solvers in computing diesel sprays. Project accomplishments are consistent with the original goals of the project. Although we acquired spatially and temporally resolved scalar measurements, they were limited to refractive index difference and not to thermodynamic properties such as temperature and equivalence ratio. However, we successfully developed the theoretical background needed to acquire such measurements at diesel conditions and demonstrated the capability of the RSD for scalar measurements in a canonical turbulent jet flow replicating features of the diesel jet. Additional work will be needed to implement these procedures at high-pressure, high-temperature engine-like conditions of the CPFR. Mainly, we did not anticipate the need to find the liquid boundary and its statistical features or the state relationships between refractive index and thermodynamic properties, assuming the widely known Dale-Gladstone equation would suffice. Still, efforts devoted to these tasks were essential to fulfil the goals of the project and serves as the foundation on which many of the conclusions and key contributions of this project are based. Further assessment and application of the developed CFD codes is recommended to fully realize the benefits of this research.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2015

Demonstration of Uncertainty Quantification and Sensitivity Analysis for PWR Fuel Performance with BISON

BISON is an advanced fuels performance code being developed at Idaho National Laboratory and is the code of choice for fuels performance by the U.S. Department of Energy (DOE)’s Consortium for Advanced Simulation of Light Water Reactors (CASL) Program. An approach to uncertainty quantification and sensitivity analysis with BISON was developed and a new toolkit was created. A PWR fuel rod model was developed and simulated by BISON, and uncertainty quantification and sensitivity analysis were performed with eighteen uncertain input parameters. The maximum fuel temperature and gap conductance were selected as the figures of merit (FOM). Pearson, Spearman, and partial correlation coefficients were considered for all of the figures of merit in sensitivity analysis.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2016

Progress In Developing An In-Pile Acoustically Telemetered Sensor Infrastructure

A salient grand challenge for a number of Department of Energy programs such as Fuels Cycle Research and Development ( includes Accident Tolerant Fuel research and the Transient Reactor Test Facility Restart experiments), Light Water Sustainability, and Advanced Reactor Technologies is to enhance our fundamental understanding of fuel and materials behavior under irradiation. Robust and accurate in-pile measurements will be instrumental to develop and validate a computationally predictive multi-scale understanding of nuclear fuel and materials. This sensing technology will enable the linking of fundamental micro-structural evolution mechanisms to the macroscopic degradation of fuels and materials. The in situ sensors and measurement systems will monitor local environmental parameters as well as characterize microstructure evolution during irradiation. One of the major road blocks in developing practical robust, and cost effective in-pile sensor systems, are instrument leads. If a wireless telemetry infrastructure can be developed for in-pile use, in-core measurements would become more attractive and effective. Thus to be successful in accomplishing effective in-pile sensing and microstructure characterization an interdisciplinary measurement infrastructure needs to be developed in parallel with key sensing technology. For the discussion in this research, infrastructure is defined as systems, technology, techniques, and algorithms that may be necessary in the delivery of beneficial and robust data from in-pile devices. The architecture of a system’s infrastructure determines how well it operates and how flexible it is to meet future requirements. The limiting path for the effective deployment of the salient sensing technology will not be the sensors themselves but the infrastructure that is necessary to communicate data from in-pile to the outside world in a non-intrusive and reliable manner. This article gives a high level overview of a promising telemetry infrastructure based on acoustic wireless transmission of data that is being developed and tested by the INL, Penn State and Westinghouse.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2022

Water limiting current measurements in anion exchange membrane fuel cells (AEMFCs); part 1: Water limiting current method development

We report water management is critical in optimizing anion exchange membrane fuel cell (AEMFCs) performance and durability. The role of membranes on determining cell water balance in AEMFCs has received limited study. A more thorough understanding of membrane water transport parameters is necessary for thorough cell optimization. In this study, a novel method for probing limiting current based on water flux across an AEMFC is presented for the first time. The water limiting current has been investigated as a function of relative humidity of anode and cathode streams, cathode backpressure and cell operating temperature. From these studies, it is clearly shown that water diffusion through the membrane from the anode is the most critical mechanism for achieving high current density performance and durability. The developed method can act as a novel screening technique that focuses on the impacts of water transport parameters and helps identify promising membrane materials based on their water transport properties. A critical but underappreciated facet of AEMFC performance and durability.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2018

Fuel Testing for Sylvatex: Cooperative Research and Development Final Report, CRADA Number CRD-16-636

Sylvatex is a green nano-chemistry company that has developed a platform technology utilizing renewable, non-toxic inputs to create a stable nanoparticle that can be used in multiple applications. Their mission is to increase the use of renewables globally, to empower a cleaner and healthier future. The main application is a fuel technology product - MicroX - that utilizes proprietary knowledge to scale low-cost, cleaner-burning renewable diesel fuel and additives by using a co-location commercial model. The aspects of this project will include testing of two Sylvatex MicroX fuels on an engine dynamometer platform. Industry standard ultra-low sulfur diesel (ULSD) B3 fuel and a ULSD B20 will both be used for comparison of the Sylvatex fuels (U.S. standard diesel fuel at the pump contains an average of approximately 3% biodiesel; this is why B3 would be used as a baseline comparison). Sylvatex is currently using a prototype formulation (MicroX 1) that applies a high cost surfactant. An experimental formulation (MicroX 2) that uses lower cost materials is under development. The MicroX 1 will be blended at a 10% level into the B3 ULSD fuel and the MicroX 2 will be blended at a 10% level into both the B3 and the B20 ULSD fuels for study on the engine dynamometer test platform. All fuel blends will be tested over the FTP transient engine test cycle and a steady state ramped modal engine test cycle. Each test cycle will be performed a minimum of 3 times for each fuel. Tailpipe and/or engine out gaseous exhaust emissions (CO2, CO, NOx, THC, O2,), engine out PM emissions, and brake-specific fuel consumption rates will be evaluated for all test cycles.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2023

BISON validation to in situ cladding burst test and high-burnup LOCA experiments

The process for developing and qualifying nuclear fuels for commercial nuclear application requires fundamental material development, characterization, and design; out-of-pile testing on unirradiated materials; integral fuel rod irradiations, testing, and postirradiation examinations; and transient analyses. The historical approach depends on the generation of large empirical datasets and series of integral fuel rod irradiations, and this approach ultimately takes ~20 years—or sometimes longer—to acquire data through extensive sequential testing. Thus, the qualification and eventual deployment of new fuel systems constitute a long process. However, recent technological advancements have provided researchers the opportunity to perform out-of-cell, in situ measurements to assess material performance for the duration of the experiment. One such example of this capability is the use of digital image coordination and thermal imaging to assess Zircaloy cladding performance under a simulated loss-of-coolant accident (LOCA) transient condition. In situ measurements generally provide high-fidelity strain, strain rates, and temperature surface maps. This is critical for the US nuclear industry, which is actively developing a technical basis to support extending the peak rod average burnup from 62 to ~75 GWd/tU and the deployment of accident-tolerant fuel. However, the US Nuclear Regulatory Commission (NRC) outlined in its research information letter several technical issues that the industry must address before extending burnup. One topic of specific interest is understanding the cladding balloon and rupture geometry during the LOCA heat-up phase. By leveraging these advanced in situ capabilities, this work used in situ data generated from a simulated LOCA to better understand high-temperature creep and its effect on Zircaloy balloon and rupture performance. Here, this work used the BISON fuel performance code to assess the high-temperature creep model predictions with in situ data.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

BISON Validation to In-Situ Cladding Burst Test and High Burnup LOCA Experiments

The process to develop and qualify nuclear fuels for commercial nuclear application requires fundamental material development, characterization, and design; out-of-pile testing on unirradiated materials; integral fuel rod irradiations, testing, and post irradiation examinations (PIEs); and transient analyses. The historical approach depends on the generation of large empirical datasets and series of integral fuel rod irradiations, and this approach ultimately takes approximately 20 years—or sometimes longer—to acquire data through extensive sequential testing. Thus, the qualification and eventual deployment of new fuel systems constitute a long and drawn-out process. However, recent technological advancements have provided researchers the opportunity to perform out-of-cell, in-situ measurements to assess material performance for the duration of the experiment. One such example of this capability is the use of digital image coordination and thermal imaging to assess Zircaloy cladding performance under a simulated loss-of-coolant accident (LOCA) transient condition. In general, the in-situ measurements provide high-fidelity strain, strain rates, and temperature surface maps. This is critical for the United States nuclear industry, which is actively developing a technical basis to support extending the peak rod average burnup from 62 to ~75 GWd/tU and the deployment of accident-tolerant fuel. However, the Nuclear Regulatory Commission, through their research information letter, outlined a number of technical issues for the industry to address before extending burnup. One topic of specific interest is understanding the cladding balloon and rupture geometry during the LOCA heatup phase. Leveraging these advanced in-situ capabilities, this work intends to use insitu data generated from a simulated LOCA in the Severe Accident Test Station at Oak Ridge National Laboratory to better understand high-temperature creep and its impact on Zircaloy balloon and rupture performance. This work used the BISON fuel performance code to compare BISON’s high-temperature creep model predictions to in-situ data and identify limitations and gaps within the model. Additionally, BISON will subsequently be used to simulate relevant high-burnup LOCA tests. The results will be analyzed and compared to the available post-test data in a manner consistent with the approach outlined in the Nuclear Regulatory Commission research information letter.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2023

Performance, Combustion and Emissions Evaluation of Liquid Phase Port-Injected LPG on a Single Cylinder Heavy-Duty Spark Ignited Engine

Liquefied petroleum gas (LPG), like many other alternative fuels, has witnessed increased adoption in the last decade, and its use is projected to rise as stricter emissions regulations continue to be applied. However, much of its use is limited to dual fuel applications, gaseous phase injection, light-duty passenger vehicle applications, or scenarios that require conversion from gasoline engines. Therefore, to address these limitations and discover the most efficient means of harnessing its full potential, more research is required in the development of optimized fuel injection equipment for liquid port and direct injection, along with the implementation of advanced combustion strategies that will improve its thermal efficiency to the levels of conventional fuels. This paper focuses on the development of a liquid phase port-injection system for LPG, the design of a reference piston, and the baseline evaluation of the performance, combustion, and emissions characteristics of a single cylinder research engine to establish a benchmark comparable to existing LPG engines. A sweep of start of injection (SOI) timing is performed by injecting liquid LPG at several closed and open intake valve timings, which demonstrates no significant variation in engine performance, but accounts for a 10% reduction in bsCO with the optimal SOI timing. Spark timing sweep demonstrates the 50% burn crank angle location related to maximum brake torque (MBT) point with a brake thermal efficiency (BTE) of ~34% for the tested load case. The effect of equivalence ratio is also presented with optimal SOI timing at MBT condition. The engine starts exhibiting knocking combustion at 140kPa intake manifold air pressure (IMAP) with a peak torque of 253Nm and a 5% reduction in brake specific fuel consumption compared to the naturally aspirated scenario.

Fosudo, Toluwalase↗

DOE OSTI2015

Effects of the shape of the foil corners on the irradiation performance of U10Mo alloy based monolithic mini-plates

Monolithic plate-type fuel is a fuel form being developed for high performance research and test reactors to minimize the use of enriched material. These fuel elements are comprised of a high density, low enrichment, U-Mo alloy based fuel foil, sandwiched between Zirconium liners and encapsulated in Aluminum cladding. The use of a high density fuel in a foil form presents a number of fabrication and operational concerns, such as: foil centering, flatness of the foil, fuel thickness variation, geometrical tilting, foil corner shape etc. To benchmark this new design, effects of various geometrical and operational variables on irradiation performance have been evaluated. As a part of these series of sensitivity studies, the shape of the foil corners were studied. To understand the effects of the corner shapes of the foil on thermo-mechanical performance of the plates, a behavioral model was developed for a selected plate from RERTR-12 experiments (Plate L1P785). Both fabrication and irradiation processes were simulated. Once the thermo-mechanical behavior the plate is understood for the nominal case, the simulations were repeated for two additional corner shapes to observe the changes in temperature, displacement and stress-strain fields. The results from the fabrication simulations indicated that the foil corners do not alter the post-fabrication stress-strain magnitudes. Furthermore, the irradiation simulations revealed that post-fabrication stresses of the foil would be relieved very quickly in operation. While, foils with chamfered and filleted corners yielded stresses with comparable magnitudes, they are slightly lower in magnitudes, and provided a more favorable mechanical response compared with the foil with sharp corners.

Finite Element Analysis↗

DOE OSTI2023

Evaluation of Nuclear Spent Fuel Disposal in Clay-Bearing Rock - Process Model Development and Experimental Studies

This report represents the milestone deliverable M2SF-23SN010301072 “Evaluation of Nuclear Spent Fuel Disposal in Clay-Bearing Rock - Process Model Development and Experimental Studies” The report provides a status update of FY23 activities for the work package Argillite Disposal work packages for the DOE-NE Spent Fuel Waste Form Science and Technology (SFWST) Program. Clay-rich geological media (often referred as shale or argillite) are among the most abundant type of sedimentary rock near the Earth’s surface. Argillaceous rock formations have the following advantageous attributes for deep geological nuclear waste disposal: widespread geologic occurrence, found in stable geologic settings, low permeability, self-sealing properties, low effective diffusion coefficient, high sorption capacity, and have the appropriate depth and thickness to host nuclear waste repository concepts. The DOE R&D program under the Spent Fuel Waste Science Technology (SFWST) campaign has made key progress (through experiment, modeling, and testing) in the study of chemical and physical phenomena that could impact the long-term safety assessment of heat-generating nuclear waste disposition in clay/shale/argillaceous rock. International collaboration activities comprising field-scale heater tests, field data monitoring, and laboratory-scale experiments provide key information on changes to the engineered barrier system (EBS) material exposed high thermal loads. Moreover, consideration of direct disposal of large capacity dual-purpose canisters (DPCs) as part of the back-end SNF waste disposition strategy has generated interest in improving our understanding of the effects of elevated temperatures on the engineered barrier system (EBS) design concepts. Chemical and structural analyses of sampled bentonite material from laboratory tests at elevated temperatures are key to the characterization of thermal effects affecting bentonite clay barrier performance. The knowledge provided by these experiments is crucial to constrain the extent of sacrificial zones in the EBS design during the thermal period. Thermal, hydrologic, mechanical, and chemical (THMC) data collected from heater tests and laboratory experiments have been used in the development, validation, and calibration of THMC simulators to model near-field coupled processes. This information leads to the development of simulation approaches to assess issues on coupled processes involving porous media flow, transport, geomechanical phenomena, chemical interactions with barrier/geologic materials, and the development of EBS concepts. These lines of knowledge are central to the design of deep geological backfilled repository concepts where temperature plays a key role in the EBS behavior, potential interactions with host rock, and long-term performance in the safety assessment.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗