Condensation Heat Transfer on Superhydrophobic Surfaces
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Integral Reactor Containment Condensation Model and Experimental Validation
This NEUP funded project, NEUP 12-3630, is for experimental, numerical and analytical studies on high-pressure steam condensation phenomena in a steel containment vessel connected to a water cooling tank, carried out at Oregon State University (OrSU) and the University of Wisconsin at Madison (UW-Madison). In the three years of investigation duration, following the original proposal, the planned tasks have been completed: (1) Performed a scaling study for the full pressure test facility applicable to the reference design for the condensation heat transfer process during design basis accidents (DBAs), modified the existing test facility to route the steady-state secondary steam flow into the high pressure containment for controllable condensation tests, and extended the operations at negative gage pressure conditions (OrSU). (2) Conducted a series of DBA and quasi-steady experiments using the full pressure test facility to provide a reliable high pressure condensation database (OrSU). (3) Analyzed experimental data and evaluated condensation model for the experimental conditions, and predicted the prototypic containment performance under accidental conditions (UW-Madison). A film flow model was developed for the scaling analysis, and the results suggest that the 1/3 scaled test facility covers large portion of laminar film flow, leading to a lower average heat transfer coefficient comparing to the prototypic value. Although it is conservative in reactor safety analysis, the significant reduction of heat transfer coefficient (50%) could under estimate the prototypic condensation heat transfer rate, resulting in inaccurate prediction of the decay heat removal capability. Further investigation is thus needed to quantify the scaling distortion for safety analysis code validation. Experimental investigations were performed in the existing MASLWR test facility at OrST with minor modifications. A total of 13 containment condensation tests were conducted for pressure ranging from 4 to 21 bar with three different static inventories of non-condensable gas. Condensation and heat transfer rates were evaluated employing several methods, notably from measured temperature gradients in the HTP as well as measured condensate formation rates. A detailed mass and energy accounting was used to assess the various measurement methods and to support simplifying assumptions required for the analysis. Condensation heat fluxes and heat transfer coefficients are calculated and presented as a function of pressure to satisfy the objectives of this investigation. The major conclusions for those tests are summarized below: (1) In the steam blow-down tests, the initial condensation heat transfer process involves the heating-up of the containment heat transfer plate. An inverse heat conduction model was developed to capture the rapid transient transfer characteristics, and the analysis method is applicable to SMR safety analysis. (2) The average condensation heat transfer coefficients for different pressure conditions and non-condensable gas mass fractions were obtained from the integral test facility, through the measurements of the heat conduction rate across the containment heat transfer plate, and from the water condensation rates measurement based on the total energy balance equation. 15 (3) The test results using the measured HTP wall temperatures are considerably lower than popular condensation models would predict mainly due to the side wall conduction effects in the existing MASLWR integral test facility. The data revealed the detailed heat transfer characteristics of the model containment, important to the SMR safety analysis and the validation of associated evaluation model. However this approach, unlike separate effect tests, cannot isolate the condensation heat transfer coefficient over the containment wall, and therefore is not suitable for the assessment of the condensation heat transfer coefficient against system pressure and noncondensable gas mass fraction. (4) The average condensation heat transfer coefficients measured from the water condensation rates through energy balance analysis are appropriate, however, with considerable uncertainties due to the heat loss and temperature distribution on the containment wall. With the consideration of the side wall conduction effects, the results indicate that the measured heat transfer coefficients in the tests is about 20% lower than the prediction of Dehbi’s correlation, mainly due to the side wall conduction effects. The investigation also indicates an increase in the condensation heat transfer coefficient at high containment pressure conditions, but the uncertainties invoked with this method appear to be substantial. (5) Non-condensable gas in the tests has little effects on the condensation heat transfer at high elevation measurement ports. It does affect the bottom measurements near the water level position. The results suggest that the heavier non-condensable gas is accumulated in the lower portion of the containment due to stratification in the narrow containment space. The overall effects of the non-condensable gas on the heat transfer process should thus be negligible for tall containments of narrow condensation spaces in most SMR designs. Therefore, the previous correlations with noncondensable gas effects are not appropriate to those small SMR containments due to the very poor mixing of steam and non-condensable gas. The MELCOR simulation results agree with the experimental data reasonably well. However, it is observed that the MELCOR overpredicts the heat flux for all analyzed tests. The MELCOR predicts that the heat fluxes for CCT’s approximately range from 30 to 45 kW/m2 whereas the experimental data (averaged) ranges from about 25 to 40 kW/m2. This may be due to the limited availability of liquid film models included in MELCOR. Also, it is believed that due to complex test geometry, measured temperature gradients across the heat transfer plate may have been underestimated and thus the heat flux had been underestimated. The MELCOR model predicts a film thickness on the order of 100 microns, which agrees very well with film flow model developed in this study for scaling analysis. However, the expected differences in film thicknesses for near vacuum and near atmospheric test conditions are not significant. Further study on the behavior of condensate film is expected to refine the simulation results. Possible refinements include but are not limited to, the followings: CFD simulation focusing on the liquid film behavior and benchmarking with experimental analyses for simpler geometries. 16 1 INTRODUCTION This NEUP funded project, NEUP 12-3630, is for experimental, numerical and analytical studies on high-pressure steam condensation phenomena in a steel containment vessel connected to a water cooling tank, carried out at Oregon State University (OrSU) and the University of Wisconsin at Madison (UW-Madison). The experimental results are employed to validate the containment condensation model in reactor containment system safety analysis code for integral SMRs. Such a containment condensation model is important to demonstrate the adequate cooling. In the three years of investigation, following the original proposal, the following planned tasks have been completed: (1) Performed a scaling study for the full pressure test facility applicable to the reference design for the condensation heat transfer process during design basis accidents (DBAs), modified the existing test facility to route the steady-state secondary steam flow into the high pressure containment for controllable condensation tests, and extended the operations at negative gage pressure conditions (OrSU). (2) Conducted a series of DBA and quasi-steady experiments using the full pressure test facility to provide a reliable high pressure condensation database (OrSU). (3) Analyzed experimental data and evaluated condensation model for the experimental conditions, and predicted the prototypic containment performance under accidental conditions (UW-Madison). The results are applicable to integral Small Modular Reactor (SMR) designs, including NuScale, mPower, Westinghouse SMR, Holtec-160 and other integral reactors with small containments of relatively high pressures under accidental conditions. Testing has been conducted at the OrSU laboratory in the existing MASLWR (Multi-Application Small Light Water Reactor) integral test facility sponsored by the US Department of Energy. Its highpressure stainless steel containment model (~2 MPa) is scaled to the NuScale SMR currently under development at NuScale Power, Inc.. Minor modifications to the model containment have been made to control the non-condensable gas fraction and to utilize the secondary loop stable steam flow for condensation testing. UW-Madison has developed a containment condensation model, which leveraged previous validated containment heat transfer work carried out at UW-Madison, and extended the range of applicability of the model to integral SMR designs that utilize containment vessels of high heat transfer efficiencies. In this final report, the research background and literature survey are presented in Chapter 2 and 3, respectively. The test facility description and modifications are summarized in Chapter 4, and the scaling analysis is introduced in Chapter 5. The tests description, procedures, and data analysis are presented in Chapter 6, while the numerical modeling is presented in Chapter 7, followed by a conclusion section in Chapter 8.
21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
New principles of self‐organization created through the interplay of DNA condensates, microtubules, and motors
Bioinspired design—which holds great promise for a new generation of materials that are robust to defects, scalable under green manufacture, environmentally responsive, and programmably reconfigurable—requires mastery over molecular self-organization. Yet, from its specific mechanisms to most general architectures, the principles governing self-organization remain poorly understood and not even fully enumerated. For living systems, one obvious architectural principle is the modular reuse of a few simple molecular components in myriad combinations to achieve more complex phenomena. For example, the mechanical tasks of a cell are driven by the nonequilibrium dynamics of cytoskeletal filaments and molecular motors—the same filaments and motors, reprogrammed by a variety of modulators, perform tasks ranging from cell movement to division. Similarly, many compartmentalization tasks are performed by liquid-like condensates of simple components, which act as membraneless organelles to localize particular molecules in space and time (e.g. for gene regulation or RNA processing). In a few cases, condensates combine and interact with the cytoskeleton to create still more complex phenomena, e.g. the nucleation of microtubule asters from the centrosome (a protein condensate) to form the mitotic spindle during cell division. Very little is known about the fundamental mechanisms of such filament-plus-condensate phenomena. Despite few examples, the landscape of behaviors that can be achieved through the combination of condensates, filaments, and motors appears vast. However, exploration has been hindered by a lack of systems that have sufficiently programmable and dynamically tunable interactions between component condensates, filaments, and motors. We proposed to combine programmable DNA condensates, filamentous microtubules, and light-controlled motors into self-organizing systems whose principles go beyond those that have been observed in nature. In one limit, our systems will use microtubules and motors to create the molecular analog of a network of roads, which will organize droplets of DNA condensates capable of carrying molecular cargo. DNA condensates coupled to motors will flow from one microtubule aster hub to another, with their direction and timing controlled by DNA circuits. In another limit, microtubules will swim through bulk DNA condensates and exhibit strong interactions with boundaries between different types of condensates. Microtubule swimmers will reflect, get trapped, or refract at boundaries, under a mechanical analog of the classical optical index of refraction. DNA condensates having different mechanical indexes of refraction will be used to construct the analog of optical lenses, so that microtubule swimmers can be manipulated like light—collimated, diffracted, focused, and sorted based on properties analogous to wavelength. These two limits define two new architectures, within which multiple new mechanistic principles for self-organization will be discovered and explored. To explore these architectures, the motor-based coupling between DNA condensates and filaments will be controlled in time and space through the use of opto-proteins that create reversible links between DNA condensates and motors upon illumination. For each principle of interest, patterns of light will create virtual experiments by defining patterns of activity where DNA condensates walk along filaments, or filaments swim through condensates, and patterns of inactivity which will serve either as controls, or as boundary conditions vital to create the desired phenomena. This research serves the goals of Basic Energy Sciences Biomolecular Material Program by elucidating the principles by which the emergent, nonequilibrium behavior of collections of DNA condensates, motors, and microtubules can be programmed by environmental light patterns to create complex motion and materials transport. Because DNA condensates can be readily coupled to virtually any high performance nanomaterial, from carbon nanotubes, to metal nanoparticles, to light harvesting systems, this work provides a path to the construction, self-maintenance and reconfiguration of materials relevant to the Department of Energy.
60 APPLIED LIFE SCIENCES↗
Laboratory Evaporation Testing Of Hanford Waste Treatment Plant Low Activity Waste Off-Gas Condensate Simulant
The Hanford Waste Treatment and Immobilization Plant (WTP) Low Activity Waste (LAW) vitrification facility will generate an aqueous condensate recycle stream, LAW Off-Gas Condensate, from the off-gas system. The baseline plan for disposition of this stream is to send it to the WTP Pretreatment Facility, where it will be blended with LAW, concentrated by evaporation and recycled to the LAW vitrification facility again. Alternate disposition of this stream would eliminate recycling of problematic components, and would enable de-coupled operation of the LAW melter and the Pretreatment Facilities. Eliminating this stream from recycling within WTP would also decrease the LAW vitrification mission duration and quantity of canistered glass waste forms. This LAW Off-Gas Condensate stream contains components that are volatile at melter temperatures and are problematic for the glass waste form. Because this stream recycles within WTP, these components accumulate in the Condensate stream, exacerbating their impact on the number of LAW glass containers that must be produced. Approximately 32% of the sodium in Supplemental LAW comes from glass formers used to make the extra glass to dilute the halides to be within acceptable concentration ranges in the LAW glass. Diverting the stream reduces the halides in the recycled Condensate and is a key outcome of this work. Additionally, under possible scenarios where the LAW vitrification facility commences operation prior to the WTP Pretreatment facility, identifying a disposition path becomes vitally important. This task examines the impact of potential future disposition of this stream in the Hanford tank farms, and investigates auxiliary evaporation to enable another disposition path. Unless an auxiliary evaporator is used, returning the stream to the tank farms would require evaporation in the 242-A evaporator. This stream is expected to be unusual because it will be very high in corrosive species that are volatile in the melter (chloride, fluoride, sulfur), will have high ammonia, and will contain carryover particulates of glass-former chemicals. These species have potential to cause corrosion of tanks and equipment, precipitation of solids, release of ammonia gas vapors, and scale in the tank farm evaporator. Routing this stream to the tank farms does not permanently divert it from recycling into the WTP, only temporarily stores it prior to reprocessing. Testing is normally performed to demonstrate acceptable conditions and limits for these compounds in wastes sent to the tank farms. The primary parameter of this phase of the test program was measuring the formation of solids during evaporation in order to assess the compatibility of the stream with the evaporator and transfer and storage equipment. The origin of this LAW Off-Gas Condensate stream will be the liquids from the Submerged Bed Scrubber (SBS) and the Wet Electrostatic Precipitator (WESP) from the LAW facility melter offgas system. The stream is expected to be a dilute salt solution with near neutral pH, and will likely contain some insoluble solids from melter carryover. The soluble components are expected to be mostly sodium and ammonium salts of nitrate, chloride, and fluoride. This stream has not been generated yet, and, thus, the composition will not be available until the WTP begins operation, but a simulant has been produced based on models, calculations, and comparison with pilot-scale tests. This report discusses results of evaporation testing of the simulant. Two conditions were tested, one with the simulant at near neutral pH, and a second at alkaline pH. The neutral pH test is comparable to the conditions in the Hanford Effluent Treatment Facility (ETF) evaporator, although that evaporator operates at near atmospheric pressure and tests were done under vacuum. For the alkaline test, the target pH was based on the tank farm corrosion control program requirements, and the test protocol and equipment was comparable to that used for routine evaluation of feed compatibility studies for the 242-A evaporator. One of the radionuclides that is volatile in the melter and expected to be in high concentration in this LAW Off-Gas Condensate stream is Technetium-99 (99Tc). Technetium will not be removed from the aqueous waste in the Hanford WTP, and will primarily end up immobilized in the LAW glass by repeated recycle of the off-gas condensate into the LAW melter. Other radionuclides that are also expected to be in appreciable concentrations in the LAW Off-Gas Condensate are 129I, 90Sr, 137Cs, and 241Am. The concentrations of these radionuclides in this stream will be much lower than in the LAW, but they will still be higher than limits for some of the other disposition pathways currently available. At this time, these scoping tests did not evaluate the partitioning of the radionuclides to the evaporator condensate, since ample data are available separately from other experience in the DOE complex. Results from the evaporation testing show that the neutral SBS simulant first forms turbidity at ~7.5X concentration, while the alkaline-adjusted simulant became turbid at ~3X concentration. The major solid in both cases was Kogarkoite, Na3FSO4. Sodium and lithium fluorides were also detected. Minimal solids were formed in the evaporator bottoms until a substantial fraction of liquid was removed, indicating that evaporation could minimize storage volume issues. Achievable concentration factors without significant insoluble solids were 17X at alkaline pH, and 23X at neutral pH. In both runs, significant ammonia carried over and was captured in the condenser with the water condensate. Results also indicate that with low insoluble solids formation in the initial testing at neutral pH, the use of Reverse Osmosis is a potential alternate method for concentrating the solution, although an evaluation is needed to identify equipment that can tolerate insoluble solids. Most of the ammonia remains in the evaporator bottoms during the neutral pH evaporation, but partitions to the condensate during alkaline evaporation. Disposition of both streams needs to consider the management of ammonia vapor and its release. Since this is an initial phase of testing, additional tasks related to evaporation methods are expected to be identified for development. These tasks likely include evaluation and testing of composition variability testing and evaluations, corrosion and erosion testing, slurry storage and immobilization investigations, and evaporator condensate disposition.
12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
Stability and Heat Transfer Characteristics of Condensing Films
The overall objective of this research is to investigate the fundamental physics of film condensation in reduced gravity. The condensation of vapor on a cool surface is important in many engineering problems,including spacecraft thermal control and also the behavior of condensate films that may form on the interior surfaces of spacecraft. To examine the effects of body force on condensing films, two different geometries have been tested in the laboratory: (1) a stabilizing gravitational body force (+1g, or condensing surface facing 'upwards') and (2) de-stabilizing gravitational body force (-1g, or 'downwards'). For each geometry, different fluid configurations are employed to help isolate the fluid mechanical and thermal mechanisms operative in condensing films. The fluid configurations are (a) a condensing film, and (b) a non-condensing film with film growth by mass addition by through the plate surface. Condensation experiments are conducted in a test cell containing a cooled copper or brass plate with an exposed diameter of 12.7 cm. The metal surface is polished to allow for double-pass shadowgraph imaging, and the test surface is instrumented with imbedded heat transfer gauges and thermocouples. Representative shadowgraph images of a condensing, unstable (-1g) n-pentane film are shown. The interfacial disturbances associated with the de-stabilizing body force leading to droplet formation and break-off can be clearly seen. The heat transfer coefficient associated with the condensing film is shown. The heat transfer coefficient is seen to initially decrease, consistent with the increased thermal resistance due to layer growth. For sufficiently long time, a steady value of heat transfer is observed, accompanied by continuous droplet formation and break-off. The non-condensing cell consists of a stack of thin stainless steel disks 10 cm in diameter mounted in a brass enclosure. The disks are perforated with a regular pattern of 361 holes each 0.25 mm in diameter. Non-condensing experiments in -1g have employed 50 cSt and 125 cSt silicone oil pumped through the perforated disks at a specified rate by a syringe micropump. The time to droplet break-off and the disturbance wavelengths appear to decrease with increasing pumping rate. The ability to reliably perform multi-point, ultrasonic measurements of the film thickness has been demonstrated. A linear array of eight transducers of 6 mm diameter (with a beam footprint of comparable size) are pulsed with a square-wave signal at a frequency of 5 MHz and a pulse duration of approximately 0.3 s. For thin films (60 m to 2-3 mm in thickness) the layer thickness is determined by frequency analysis, where the received ultrasound pulse is Fourier transformed and the spacing between the peaks in the frequency spectrum is analyzed. For thicker layers (up to at least 1 cm in thickness), time-domain analysis is performed of the received ultrasound pulses to generate directly the layer thickness. A time-trace of the film thickness at a point using a single transducer in the linear array is shown for the case of an unstable (-1g) n-pentane film. The oscillations in film thickness are evidently due to the passage and/or shedding of droplets from the cooled plate surface. The entire transducer array was used to measure the changes in film thickness resulting from the passage of gravity waves generated either by an oscillating wall or the impact of a single droplet on the free surface of a film. The enclosure in both cases was 14 cm square and the transducer spacing was 12 mm. Best results were obtained using as test fluid a mixture of 50% glycerol and 50% water with a fluid layer thickness of 3-5 mm. In both cases the measured wavelengths and wave propagation speeds using the ultrasound technique compared reasonably well with those observed by optical imaging. Additional information can be found in the original extended abstract.
Hermanson, J. C.↗
Gravity Effects in Condensing and Evaporating Films
A general overview of gravity effects in condensing and evaporating films is presented. The topics include: 1) Research Overview; 2) NASA Recognizes Critical Need for Condensation & Evaporation Research to Enable Human Exploration of Space; 3) Condensation and Evaporation Research in Reduced Gravity is Enabling for AHST Technology Needs; 4) Differing Role of Surface Tension on Condensing/Evaporating Film Stability; 5) Fluid Mechanisms in Condensing and Evaporating Films in Reduced Gravity; 6) Research Plan; 7) Experimental Configurations for Condensing Films; 8) Laboratory Condensation Test Cell; 9) Aircraft Experiment; 10) Condensation Study Current Test Conditions; 11) Diagnostics; 12) Shadowgraph Images of Condensing n- pentane Film in Unstable (-1g) Configuration; 13) Condensing n-Pentane Film in Normal Gravity (-1g) at Constant Pressure; 14) Condensing n-Pentane Film in Normal Gravity (-1g) with Cyclic Pressure; 15) Non-condensing Pumped Film in Normal Gravity (-1g); 16) Heat Transfer Coefficient in Developing, Unstable Condensing Film in Normal Gravity; 17) Heat Transfer for Unsteady Condensing Film (-1g); 18) Ultrasound Measurement of Film Thickness N-pentane Film, Stable (+1g) Configuration; and 19) Ultrasound Measurement of Film Thickness N-pentane Film, Unstable (-1g) Configuration.
Hermanson, J. C.↗
Robust silane self-assembled monolayer coatings on plasma-engineered copper surfaces promoting dropwise condensation
Dropwise condensation is well known to result in better heat transfer performance owing to efficient condensate/droplet removal, which can be harnessed in various industrial heat/mass transfer applications such as power generation and conversion, water harvesting/desalination, and electronics thermal management. The key to enhancing condensation via the dropwise mode is thin low surface energy coatings (<100 nm) with low contact angle hysteresis. Ultrathin (<5 nm) silane self-assembled monolayers (or SAMs) have been widely studied to promote dropwise condensation due to their minimal thermal resistance and scalable integration processes. Such thin coatings typically degrade within an hour during condensation of water vapor. After coating failure, water vapor condensation transitions to the inefficient filmwise mode with poor heat transfer performance. We enhance silane SAM quality and durability during water vapor condensation on copper compared to state-of-the-art silane coatings on metal surfaces. We achieve this via (i) surface polishing to sub-10 nm levels, (ii) pure oxygen plasma surface treatment, and (iii) silane coating integration with the copper substrate in an anhydrous/moisture-free environment. The resulting silane SAM has low contact angle hysteresis (≈20°) and promotes efficient dropwise condensation of water for >360 hours without any visible sign of coating failure/degradation in the absence of non-condensable gases. We further demonstrate enhanced heat transfer performance (≈5-7× increase over filmwise condensation) over an extended period of time. Surface characterization data post-condensation leads us to propose that in the absence of non-condensable gases in the vapor environment, the silane SAM degrades due to reduction and subsequent dissolution of copper oxide at the oligomer-substrate interface. The experiments also indicate that the magnitude of surface subcooling (or condensation rate) affects the rate of coating degradation. Finally, this work identifies a pathway to durable dropwise promoter coatings that will enable efficient heat transfer in industrial applications.
42 ENGINEERING↗
Improved Heat Exchanger Performance Achieved Through Improved Condensate Drainage - 18478
Hanford's 242-A Evaporator has had the mission of reducing waste volume in the Hanford Tank Farms since the late 1970's. At the very heart of the 242-A evaporation process is the E-A-1 reboiler, a heat exchanger which adds heat to the waste, and the vacuum condenser system, a three-stage condenser/ejector system which condenses the waste vapors and provides the vacuum at which the evaporation process operates. Over a long period of time, significant degraded performance has been observed in the heat exchangers in both the heating system and in the vacuum condensing system. This degraded performance was indicative of degraded conditions in equipment and/or piping associated with both the heating and vacuum condenser systems. However, in searching for degraded condition in these systems, 242-A engineering also discovered that both systems contained design errors in the condensate drainage associated with all heat exchangers in both systems. By addressing the condensate design errors in addition to correcting the degraded conditions, system performance was restored and even possibly improved. All heat exchangers in the heating and vacuum condensing systems are shell and tube type heat exchangers. Both have liquid on the tube side and vapor on the shell side (in the case of the reboiler the liquid is tank waste and the vapor is 10 lb heating steam, and in the case of the vacuum condensers the liquid is cooling water and the vapor is waste vapor). In both systems, engineering proposed that the vapor condensate was backing up into the heat exchanger, resulting in added poor performance. By focusing on basic heat exchanger system design, projects were initiated to redesign the condensate drainage of these systems and re-plumb the condensate drain lines. Data collected before and after the replumbing provides evidence that the corrected drain lines from the heat exchangers improved the performance of the system as a whole, and in the case of the reboiler, removed a potentially damaging steam condensate water hammer condition. (author)
12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
Enhanced condensation heat transfer using porous silica inverse opal coatings on copper tubes
Abstract Phase-change condensation is commonplace in nature and industry. Since the 1930s, it is well understood that vapor condenses in filmwise mode on clean metallic surfaces whereas it condenses by forming discrete droplets on surfaces coated with a promoter material. In both filmwise and dropwise modes, the condensate is removed when gravity overcomes pinning forces. In this work, we show rapid condensate transport through cracks that formed due to material shrinkage when a copper tube is coated with silica inverse opal structures. Importantly, the high hydraulic conductivity of the cracks promote axial condensate transport that is beneficial for condensation heat transfer. In our experiments, the cracks improved the heat transfer coefficient from ≈ 12 kW/m 2 K for laminar filmwise condensation on smooth clean copper tubes to ≈ 80 kW/m 2 K for inverse opal coated copper tubes; nearly a sevenfold increase from filmwise condensation and identical enhancement with state-of-the-art dropwise condensation. Furthermore, our results show that impregnating the porous structure with oil further improves the heat transfer coefficient by an additional 30% to ≈ 103 kW/m 2 K. Importantly, compared to the fast-degrading dropwise condensation, the inverse opal coated copper tubes maintained high heat transfer rates when the experiments were repeated > 20 times; each experiment lasting 3–4 h. In addition to the new coating approach, the insights gained from this work present a strategy to minimize oil depletion during condensation from lubricated surfaces.
Adera, Solomon↗
Clean Condensing Gas Furnace
Natural gas furnaces are the most common space heating equipment in the U.S. residential and commercial building markets. However, current residential natural gas condensing furnaces generate substantial acidic condensate as well as significant emissions of sulfur oxides (SOx), nitrogen oxides (NOx), carbon monoxide (CO), hydrocarbons (HC), and methane (CH 4 ) contributing to environmental degradation of air, water, and soil. This report describes a novel solution to reduce the environmental impact of natural gas condensing furnaces based on the technology of a monolithic acidic gas reduction (AGR) catalyst for SOx trapping, NOx redox to nitrogen, and oxidation of formic acid, CO, HC, and CH 4 . The AGR technology offers the following benefits: (1) a neutral furnace condensate with a pH of ~7, allowing its safe release into the sewer system thus eliminating a second drainage system; (2) trapping and removing nearly all SOx emissions; (3) NOx emissions nearly at nearly 1-2 ng/J, more than 95% lower than new emissions standards in California; (4) the use of a low-cost heat exchanger as a condensing heat exchanger (HX) since the condensate is not acidic, avoiding the need for expensive stainless steel alloys; and (5) unburnt fuel energy recovery to boost efficiency.The AGR component and AGR-enabled furnace performance were broadly tested to determine their effects on long-term reliability and durability, as well as SOx storage and regeneration activity. The AGR regeneration does not impair the performance in achieving neutral condensate and ultra-low NOx emissions, and the AGR catalyst subjected to regeneration activities continued to function well and achieved slightly better annual fuel utilization efficiency (AFUE). The 400-hour reliability and durability test of the retrofitted condensing furnace with the AGR component shows that the furnace unit still achieves a neutral furnace condensate with a pH of ~7 and enables 0~3 ng/J of NOx emissions. However, the 400-hour operation slightly degraded the AFUE because of soot particle accumulation caused by frequent incomplete combustion owing to inappropriate condensate drainage during testing. Thus, proper condensate drainage is critical for AGR-enabled furnaces. Furthermore, neutron computed tomography was employed to survey the aged AGR component and demonstrate high-resolution 2D and 3D representations for the nondestructive diagnosis of the AGR component. The tomography showed that the AGR component did not deform or suffer broken AGR channels. A new AGR catalyst with low precious metal loading was preliminarily explored to identify a pathway of optimizing AGR material loading and maximizing acidic gas reduction at low cost. The new AGR component can reduce precious metal loading by 38% and still achieve neutral condensate and ultralow NOx emissions. The furnace with the AGR component of low Pt/Rh loading enables a maximum AFUE of 97%, which is meaningfully higher than the original furnace. Long-duration testing for the furnace enabled with the low precious metal loading AGR component will be vital in future research. Although the current work demonstrates a proof of concept for the AGR-enabled furnace, the AGR assembly needs to be optimized and integrated into the design of new OEM furnace products. Furthermore, the AGR technology can be applied not only for residential gas furnaces, but also for commercial rooftop units, gas heat pumps, gas-fired water heaters, combustion boilers, and other systems.
03 NATURAL GAS↗
Cloud response to co-condensation of water and organic vapors over the boreal forest
Abstract. Accounting for the condensation of organic vapors along with water vapor (co-condensation) has been shown in adiabatic cloud parcel model (CPM) simulations to enhance the number of aerosol particles that activate to form cloud droplets. The boreal forest is an important source of biogenic organic vapors, but the role of these vapors in co-condensation has not been systematically investigated. In this work, the environmental conditions under which strong co-condensation-driven cloud droplet number enhancements would be expected over the boreal biome are identified. Recent measurement technology, specifically the Filter Inlet for Gases and AEROsols (FIGAERO) coupled to an iodide-adduct chemical ionization mass spectrometer (I-CIMS), is utilized to construct volatility distributions of the boreal atmospheric organics. Then, a suite of CPM simulations initialized with a comprehensive set of concurrent aerosol observations collected in the boreal forest of Finland during spring 2014 is performed. The degree to which co-condensation impacts droplet formation in the model is shown to be dependent on the initialization of temperature, relative humidity, updraft velocity, aerosol size distribution, organic vapor concentration, and the volatility distribution. The predicted median enhancements in cloud droplet number concentration (CDNC) due to accounting for the co-condensation of water and organics fall on average between 16 % and 22 %. This corresponds to activating particles 10–16 nm smaller in dry diameter that would otherwise remain as interstitial aerosol. The highest CDNC enhancements (ΔCDNC) are predicted in the presence of a nascent ultrafine aerosol mode with a geometric mean diameter of ∼ 40 nm and no clear Hoppel minimum, indicative of pristine environments with a source of ultrafine particles (e.g., via new particle formation processes). Such aerosol size distributions are observed 30 %–40 % of the time in the studied boreal forest environment in spring and fall when new particle formation frequency is the highest. To evaluate the frequencies with which such distributions are experienced by an Earth system model over the whole boreal biome, 5 years of UK Earth System Model (UKESM1) simulations are further used. The frequencies are substantially lower than those observed at the boreal forest measurement site (< 6 % of the time), and the positive values, peaking in spring, are modeled only over Fennoscandia and the western parts of Siberia. Overall, the similarities in the size distributions between observed and modeled (UKESM1) are limited, which would limit the ability of this model, or any model with a similar aerosol representation, to project the climate relevance of co-condensation over the boreal forest. For the critical aerosol size distribution regime, ΔCDNC is shown to be sensitive to the concentrations of semi-volatile and some intermediate-volatility organic compounds (SVOCs and IVOCs), especially when the overall particle surface area is low. The magnitudes of ΔCDNC remain less affected by the more volatile vapors such as formic acid and extremely low- and low-volatility organic compounds (ELVOCs and LVOCs). The reasons for this are that most volatile organic vapors condense inefficiently due to their high volatility below the cloud base, and the concentrations of LVOCs and ELVOCs are too low to gain significant concentrations of soluble mass to reduce the critical supersaturations enough for droplet activation to occur. A reduction in the critical supersaturation caused by organic condensation emerges as the main driver of the modeled ΔCDNC. The results highlight the potential significance of co-condensation in pristine boreal environments close to sources of fresh ultrafine particles. For accurate predictions of co-condensation effects on CDNC, also in larger-scale models, an accurate representation of the aerosol size distribution is critical. Further studies targeted at finding observational evidence and constraints for co-condensation in the field are encouraged.
54 ENVIRONMENTAL SCIENCES↗
Film condensation in a horizontal rectangular duct
Condensation heat transfer in an annular flow regime with and without interfacial waves was experimentally investigated. The study included measurements of heat transfer rate with condensation of vapor flowing inside a horizontal rectangular duct and experiments on the initiation of interfacial waves in condensation, and adiabatic air-liquid flow. An analytical model for the condensation was developed to predict condensate film thickness and heat transfer coefficients. Some conclusions drawn from the study are that the condensate film thickness was very thin (less than 0.6 mm). The average heat transfer coefficient increased with increasing the inlet vapor velocity. The local heat transfer coefficient decreased with the axial distance of the condensing surface, with the largest change at the leading edge of the test section. The interfacial shear stress, which consisted of the momentum shear stress and the adiabatic shear stress, appeared to have a significant effect on the heat transfer coefficients. In the experiment, the condensate flow along the condensing surface experienced a smooth flow, a two-dimensional wavy flow, and a three-dimensional wavy flow. In the condensation experiment, the local wave length decreased with the axial distance of the condensing surface and the average wave length decreased with increasing inlet vapor velocity, while the wave speed increased with increasing vapor velocity. The heat transfer measurements are reliable. And, the ultrasonic technique was effective for measuring the condensate film thickness when the surface was smooth or had waves of small amplitude.
Lu, Qing↗
Development of Scaling Criteria for Modeling Condensation in Horizontal Tubes Using Reduced Pressure System and Simulant Fluid
Most of the currently operating nuclear power plants (NPPs), generation-II and III, are equipped with active safety systems, which raises concerns regarding those safety systems' operational reliability and the suitability of the accidents prevention measures. Following the severe accidents at nuclear power plants at Three Mile Island, Chernobyl, and recently in Fukushima some advance Pressurized Water Reactors (PWRs) have adopted passively cooled steam generator natural circulation system to remove the decay heat passively through the steam generator (SG). This is done by condensing steam from the steam generator inside a heat exchanger submerged in a tank of water or an air cooled system. The APR+ (Advanced Power Reactor Plus), which is currently being developed in South Korea, has adopted a Passive Auxiliary Feedwater System (PAFS), which removes the decay heat through the steam generator replacing the conventional active auxiliary feedwater system. The main part of the PAFS, in where the steam condenses, is the Passive Condensation Heat Exchanger (PCHX). The steam condenses under high pressure (7.4 MPa, 290 deg. C) in 8.4 m long horizontal tube, with 3 degrees inclination, with inner diameter of 44.8 mm and wall thickness of 3 mm. The PCHX consists of 4 bundles, each bundle has 60 condensation tubes. The performance of the PCHX performance should be evaluated. Condensation has been extensively studied; however, most previous experimental work was directed to low pressure (i.e., near atmospheric pressure) and small condensation tubes. Moreover, studies on the horizontal type heat exchanger are limited, since previous safety systems and experimentation work were directed to the vertical type heat exchangers. Due to the high construction cost of a full size high pressure condensation experiment, a reduced-size reduced-pressure condensation experiment is suggested to evaluate the heat removal performance of a condensation tube of the PAFS heat exchanger. A scaling methodology to be established to design a reduced-size reduced-pressure condensation experiment. This study attempts to develop a scaling criteria for the PAFS condensation system, and to apply it for modeling a high pressure water system by a low pressure Freon system.
21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
Technoeconomic Benefits of Film-Forming Amine Products Applied to Steam Surface Condensers
In a conventional Rankine cycle, the majority of power plants employ surface condensers that use pumped cooling water to reject heat from the cycle. In such cases, heat rejection occurs in a shell and tube heat exchanger by film-wise condensation of low-pressure steam on stainless steel, titanium, brass, or copper-nickel tubing. To improve the thermal performance of steam surface condensers, a replenishable film-forming substance (FFS) can be ap-plied to the condenser tubing to promote efficient dropwise condensation. Conventionally, film-forming amine prod-uct (FFAP) coatings protect boiler surfaces from oxidative corrosion, which substantially reduces the operation and maintenance costs. To quantify the technical and economic benefits of FFAP coatings applied to condenser tubing due to the promotion of dropwise condensation, a thermal resistance network model was established. Using a rep-resentative steam surface condenser, the improvements in thermal performance (overall heat transfer coefficient) and process parameters (net plant efficiency, cooling water flowrate, and turbine backpressure) were determined due to the enhancement in the condensation heat transfer coefficient. Experimentally measured condensation heat transfer coefficients for common condenser materials were compared with the modeling results and were found to be within attainable bounds. Lastly, the trend in total heat exchanger cost reduction is generalized to understand the trade-off between reduced surface area for heat rejection and increase in coating application costs for a re-plenishable coating system.
20 FOSSIL-FUELED POWER PLANTS↗
Condensation and dissociation rates for gas phase metal clusters from molecular dynamics trajectory calculations
In gas phase synthesis systems, clusters form and grow via condensation, in which a monomer binds to an existing cluster. While a hard sphere equation is frequently used to predict the condensation rate coefficient, this equation neglects the influences of potential interactions and cluster internal energy on the condensation process. Here, we present a collision rate theory-Molecular Dynamics simulation approach to calculate condensation probabilities and condensation rate coefficients; we use this approach to examine atomic condensation onto 6-56 atom Au and Mg clusters. The probability of condensation depends upon the initial relative velocity ( v ) between atom and cluster and the initial impact parameter ( b ). In all cases there is a well-defined region of b-v space where condensation is highly probable, and outside of which the condensation probability drops to zero. For Au clusters with more than 10 atoms, we find that at gas temperatures in the 300-1200 K range, the condensation rate coefficient exceeds the hard sphere rate coefficient by a factor of 1.5-2.0. Conversely, for Au clusters with 10 or fewer atoms, and for 14 atom and 28 atom Mg clusters, as cluster equilibration temperature increases the condensation rate coefficient drops to values below the hard sphere rate coefficient. Calculations also yield the self-dissociation rate coefficient, which is found to vary considerably with gas temperature. Finally, calculations results reveal that grazing (high b ) atom-cluster collisions at elevated velocity (> 1000 m s -1 ) can result in the colliding atom rebounding (bounce) from the cluster surface or binding while another atom dissociates (replacement). In conclusion, the presented method can be applied in developing rate equations to predict material formation and growth rates in vapor phase systems.
77 NANOSCIENCE AND NANOTECHNOLOGY↗
Simultaneous fermion and exciton condensations from a model Hamiltonian
Fermion-exciton condensation in which both fermion-pair (i.e., superconductivity) and exciton condensations occur simultaneously in a single coherent quantum state has recently been conjectured to exist. Here, we capture the fermion-exciton condensation through a model Hamiltonian that can recreate the physics of this new class of highly correlated condensation phenomena. We demonstrate that the Hamiltonian generates the large-eigenvalue signatures of fermion-pair and exciton condensations for a series of states with increasing particle numbers. The results confirm that the dual-condensate wave function arises from the entanglement of fermion-pair and exciton wave functions, which we previously predicted in the thermodynamic limit. Furthermore, this model Hamiltonian—generalizing well-known model Hamiltonians for either superconductivity or exciton condensation—can explore a wide variety of condensation behavior. It provides significant insights into the required forces for generating a fermion-exciton condensate, which will likely be invaluable for realizing such condensations in realistic materials with applications from superconductors to excitonic materials.
75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
HDX–MS finds that partial unfolding with sequential domain activation controls condensation of a cellular stress marker
Eukaryotic cells form condensates to sense and adapt to their environment [S. F. Banani, H. O. Lee, A. A. Hyman, M. K. Rosen,Nat. Rev. Mol. Cell Biol.18, 285–298 (2017), H. Yoo, C. Triandafillou, D. A. Drummond,J. Biol. Chem.294, 7151–7159 (2019)]. Poly(A)-binding protein (Pab1), a canonical stress granule marker, condenses upon heat shock or starvation, promoting adaptation [J. A. Ribacket al.,Cell168, 1028–1040.e19 (2017)]. The molecular basis of condensation has remained elusive due to a dearth of techniques to probe structure directly in condensates. We apply hydrogen–deuterium exchange/mass spectrometry to investigate the mechanism of Pab1’s condensation. Pab1’s four RNA recognition motifs (RRMs) undergo different levels of partial unfolding upon condensation, and the changes are similar for thermal and pH stresses. Although structural heterogeneity is observed, the ability of MS to describe populations allows us to identify which regions contribute to the condensate’s interaction network. Our data yield a picture of Pab1’s stress-triggered condensation, which we term sequential activation (Fig. 1A), wherein each RRM becomes activated at a temperature where it partially unfolds and associates with other likewise activated RRMs to form the condensate. Subsequent association is dictated more by the underlying free energy surface than specific interactions, an effect we refer to as thermodynamic specificity. Our study represents an advance for elucidating the interactions that drive condensation. Furthermore, our findings demonstrate how condensation can use thermodynamic specificity to perform an acute response to multiple stresses, a potentially general mechanism for stress-responsive proteins.
Science & Technology - Other Topics↗