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All sources NASA NTRS DOE OSTI

DOE OSTI2016

Multiphysics modeling of two-phase film boiling within porous corrosion deposits

Porous corrosion deposits on nuclear fuel cladding, known as CRUD, can cause multiple operational problems in light water reactors (LWRs). CRUD can cause accelerated corrosion of the fuel cladding, increase radiation fields and hence greater exposure risk to plant workers once activated, and induce a downward axial power shift causing an imbalance in core power distribution. In order to facilitate a better understanding of CRUD's effects, such as localized high cladding surface temperatures related to accelerated corrosion rates, we describe an improved, fully-coupled, multiphysics model to simulate heat transfer, chemical reactions and transport, and two-phase fluid flow within these deposits. Our new model features a reformed assumption of 2D, two-phase film boiling within the CRUD, correcting earlier models' assumptions of single-phase coolant flow with wick boiling under high heat fluxes. This model helps to better explain observed experimental values of the effective CRUD thermal conductivity. Finally, we propose a more complete set of boiling regimes, or a more detailed mechanism, to explain recent CRUD deposition experiments by suggesting the new concept of double dryout specifically in thick porous media with boiling chimneys. - Highlights: • A two-phase model of CRUD's effects on fuel cladding is developed and improved. • This model eliminates the formerly erroneous assumption of wick boiling. • Higher fuel cladding temperatures are predicted when accounting for two-phase flow. • Double-peaks in thermal conductivity vs. heat flux in experiments are explained. • A “double dryout” mechanism in CRUD is proposed based on the model and experiments.

42 ENGINEERING↗

DOE OSTI2025

Enhanced pool boiling heat transfer using novel inverted trapezoid microgroove structures

Pool boiling heat transfer improvements with enhanced surfaces have been extensively studied for various hydrofluorocarbon (HFC) refrigerants. However, there is a limited number of studies in the open literature that focus on the pool boiling heat transfer characteristics of hydrofluoroolefin (HFO) refrigerants on enhanced surfaces. This study aims to address this gap by analyzing the pool boiling behavior of HFO refrigerants, specifically R1234yf and R1234ze(E). Experiments were conducted on both plain surfaces and novel inverted trapezoid microgroove structures. Further, the experimental results indicate that the microgroove structures can improve heat transfer coefficients by up to 80% compared to plain surfaces. Additionally, the performance of R1234yf and R1234ze(E) was compared to that of R134. It was observed that R1234yf exhibited comparable performance to R134a, while R1234ze(E) showed slightly lower performance. To assess the influence of saturation temperature on pool boiling heat transfer, tests were conducted at different saturation temperatures of 15℃, 25℃, and 35℃. The findings revealed that the pool boiling heat transfer coefficient increases with rising saturation temperature.

42 ENGINEERING↗

DOE OSTI2026

Capture, storage, and re-use of liquid hydrogen boil-off for aviation and aerospace applications

Despite major interest in the use of liquid hydrogen as a fuel for aviation and aerospace sectors, loss of hydrogen through boil-off continues to be a hurdle as it causes financial loss, indirect greenhouse gas emissions, and safety concerns. Herein, we perform techno-economic analysis, calibrated with experimental measurements, to assess the use of sorbents to capture and condition hydrogen boil-off events in the range of 1.5 to 70 tonnes per day at launch sites and airports. We evaluate the direct delivery of captured boil-off to combustion engines and fuel cells, comparing against boil-off re-liquification and compression. Results indicate probable cost-effectiveness at delivered liquid hydrogen prices above 0.9 U.S. dollar ($) per kg H2 at airports, and above 10 $ per kg H2 at launch sites where 10% or more of hydrogen is lost to boil-off.

08 HYDROGEN↗

DOE OSTI2016

Atomistic modelling of evaporation and explosive boiling of thin film liquid argon over internally recessed nanostructured surface

Molecular dynamics (MD) simulations have been carried out to investigate evaporation and explosive boiling phenomena of thin film liquid argon on nanostructured solid surface with emphasis on the effect of solid-liquid interfacial wettability. The nanostructured surface considered herein consists of trapezoidal internal recesses of the solid platinum wall. The wetting conditions of the solid surface were assumed such that it covers both the hydrophilic and hydrophobic conditions and hence effect of interfacial wettability on resulting evaporation and boiling phenomena was the main focus of this study. The initial configuration of the simulation domain comprised of a three phase system (solid platinum, liquid argon and vapor argon) on which equilibrium molecular dynamics (EMD) was performed to reach equilibrium state at 90 K. After equilibrium of the three-phase system was established, the wall was set to different temperatures (130 K and 250 K for the case of evaporation and explosive boiling respectively) to perform non-equilibrium molecular dynamics (NEMD). The variation of temperature and density as well as the variation of system pressure with respect to time were closely monitored for each case. The heat flux normal to the solid surface was also calculated to illustrate the effectiveness of heat transfer for hydrophilic and hydrophobic surfaces in cases of both nanostructured surface and flat surface. The results obtained show that both the wetting condition of the surface and the presence of internal recesses have significant effect on normal evaporation and explosive boiling of the thin liquid film. The heat transfer from solid to liquid in cases of surface with recesses are higher compared to flat surface without recesses. Also the surface with higher wettability (hydrophilic) provides more favorable conditions for boiling than the low-wetting surface (hydrophobic) and therefore, liquid argon responds quickly and shifts from liquid to vapor phase faster in case of hydrophilic surface. The heat transfer rate is also much higher in case of hydrophilic surface.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

NASA NTRS1962

BOILING HEAT TRANSFER TO LIQUID HYDROGEN AND NITROGEN IN FORCED FLOW

Boiling heat transfer to liquid hydrogen and nitrogen was investigated experimentally. Results are presented from a study of bulk boiling inside a cylindrical tube under vertically upward forced-flow conditions. A 0.555-inch-inside-diameter and 16 (1/8)-inch-long electrically heated stainless-steel tube was used. The range of variables studied for hydrogen were mass velocity of 2850 to 17,000 pounds per hour per square foot, local heat flux of 3600 to 40,000 Btu per hour per square foot, inlet pressure of 30 to 74 pounds per square inch absolute, and inlet subcooling of 0° to 9° R. Nitrogen test conditions were mass velocity of 15,000 to 56,000 pounds per hour per square foot, local heat flux of 2300 to 40,000 Btu per hour per square foot, inlet pressure of 47 to 56 pounds per square inch absolute, and inlet sub cooling of 1° to 6° R. The axial distribution of the tube-wall temperatures is presented. A transition in the type of boiling heat transfer was obtained. The critical heat flux corresponding to this transition was determined over a range of flow and heating rates and local qualities. At specific combinations of flow and transition location, a range of critical-heat-flux values was obtained and maximum values were determined. The maximum critical heat flux increased with increasing fluid-flow rate and decreased with increasing length of tube before transition. Similar variations of the maximum critical heat flux have been reported for water. The tube-inner-wall temperatures upstream of transition were essentially uniform and were only slightly greater than the fluid saturation temperature. The Wall-temperature profiles downstream of transition generally resembled those obtained in film-boiling studies and appeared to be strongly dependent upon local quality at the point of transition. Maximum wall temperatures of 9000 and 18000 R were obtained with hydrogen and nitrogen, respectively. Fluctuations of pressure, flow rate, and temperature occurred during some of the boiling tests. Under some conditions, maximum critical-heat-flux values were attained during steady-state operation with fluctuations. In other cases the fluctuations became uncontrolled, and critical-flux values less than the maximum values were obtained upon restabilization of the test conditions. No measurable pressure drop across the test section was obtained at any condition.

LIQUID HYDROGEN↗

NASA NTRS2014

Cryogenic Boil-Off Reduction System Testing

Cryogenic propellants such as liquid hydrogen (LH2) and liquid oxygen (LO2) are a part of NASA's future space exploration due to the high specific impulse that can be achieved using engines suitable for moving 10's to 100's of metric tons of payload mass to destinations outside of low earth orbit. However, the low storage temperatures of LH2 and LO2 cause substantial boil-off losses for missions with durations greater than several days. The losses can be greatly reduced by incorporating high performance cryocooler technology to intercept heat load to the propellant tanks and by the integration of self-supporting multi-layer insulation. The active thermal control technology under development is the integration of the reverse turbo- Brayton cycle cryocooler to the propellant tank through a distributed cooling network of tubes coupled to a shield in the tank insulation and to the tank wall itself. Also, the self-supporting insulation technology was utilized under the shield to obtain needed tank applied LH2 performance. These elements were recently tested at NASA Glenn Research Center in a series of three tests, two that reduced LH2 boil-off and one to eliminate LO2 boil-off. This test series was conducted in a vacuum chamber that replicated the vacuum of space and the temperatures of low Earth orbit. The test results show that LH2 boil-off was reduced 60% by the cryocooler system operating at 90K and that robust LO2 zero boil-off storage, including full tank pressure control was achieved.

Propellant Storage↗

NASA NTRS2015

Numerical Investigation of Microgravity Tank Pressure Rise Due to Boiling

The ability to control self-pressurization in cryogenic storage tanks is essential for NASAs long-term space exploration missions. Predictions of the tank pressure rise in Space are needed in order to inform the microgravity design and optimization process. Due to the fact that natural convection is very weak in microgravity, heat leaks into the tank can create superheated regions in the liquid. The superheated regions can instigate microgravity boiling, giving rise to pressure spikes during self-pressurization. In this work, a CFD model is developed to predict the magnitude and duration of the microgravity pressure spikes. The model uses the Schrage equation to calculate the mass transfer, with a different accommodation coefficient for evaporation at the interface, condensation at the interface, and boiling in the bulk liquid. The implicit VOF model was used to account for the moving interface, with bounded second order time discretization. Validation of the models predictions was carried out using microgravity data from the Tank Pressure Control Experiment, which flew aboard the Space Shuttle Mission STS-52. Although this experiment was meant to study pressurization and pressure control, it underwent boiling during several tests. The pressure rise predicted by the CFD model compared well with the experimental data. The ZBOT microgravity experiment is scheduled to fly on February 2016 aboard the ISS. The CFD model was also used to perform simulations for setting parametric limits for the Zero-Boil-Off Tank (ZBOT) Experiments Test Matrix in an attempt to avoid boiling in the majority of the test runs that are aimed to study pressure increase rates during self-pressurization. *Supported in part by NASA ISS Physical Sciences Research Program, NASA HQ, USA

pressure rise↗

NASA NTRS2016

Flow Boiling and Condensation Experiment (FBCE) for the International Space Station

An effective means to reducing the size and weight of future space vehicles is to replace present mostly single-phase thermal management systems with two-phase counterparts. By capitalizing upon both latent and sensible heat of the coolant rather than sensible heat alone, two-phase thermal management systems can yield orders of magnitude enhancement in flow boiling and condensation heat transfer coefficients. Because the understanding of the influence of microgravity on two-phase flow and heat transfer is quite limited, there is an urgent need for a new experimental microgravity facility to enable investigators to perform long-duration flow boiling and condensation experiments in pursuit of reliable databases, correlations and models. This presentation will discuss recent progress in the development of the Flow Boiling and Condensation Experiment (FBCE) for the International Space Station (ISS) in collaboration between Purdue University and NASA Glenn Research Center. Emphasis will be placed on the design of the flow boiling module and on new flow boiling data that were measured in parabolic flight, along with extensive flow visualization of interfacial features at heat fluxes up to critical heat flux (CHF). Also discussed a theoretical model that will be shown to predict CHF with high accuracy.

flow boiling↗

NASA NTRS2023

Validation of Universal Cryogenic Flow Boiling Correlations in Thermal Desktop for Liquid Helium

Understanding two-phase cryogenic propellant behavior is key to enabling technologies for future spaceflight missions. Developing accurate models of two-phase flow phenomena, particularly flow boiling in the heating configuration is relevant to the propellant transfer process both in microgravity and on other planetary surfaces. Currently there is a need for more accurate, direct cryogenic data anchored models for various boiling phenomena. Recently, universal correlations for cryogens flowing in heated tubes have been developed for a wide variety of fluids, thermodynamic conditions, and various regimes across the boiling curve, and have been patched to provide a smooth, continuous predictive curve. This paper demonstrates how these correlations have been ported into Thermal Desktop to improve predictive performance. To test the validity of the new correlations, Thermal Desktop is validated against a historical dataset of flow boiling experiments in the heating configuration using liquid helium. Based on results, the new correlations show a substantial improvement over the original built-in flow boiling correlations in Thermal Desktop in predicting the wall temperature as a function of preponderant parameters for this quantum fluid.

cryogenic propellant transfer↗

NASA NTRSDate not supplied

Validation of Universal Cryogenic Flow Boiling Correlations in Thermal Desktop for Liquid Helium

Understanding two-phase cryogenic propellant behavior is key to enabling technologies for future spaceflight missions. Developing accurate models of two-phase flow phenomena, particularly in the current work, flow boiling in the heating configuration, is relevant to the propellant transfer process both in 1-g and microgravity. Currently there is a need for more accurate, direct cryogenic data anchored models for various boiling phenomena. Recently, universal correlations for cryogens flowing in heated tubes have been developed for a wide variety of fluids, thermodynamic conditions, and various regimes across the boiling curve, and have been patched to provide a smooth, continuous predictive curve. This paper describes implementation and validation of these correlations into Thermal Desktop to improve predictive performance, with a focus on liquid helium. Results from Thermal Desktop using both the built-in and new correlations are validated against a historical dataset of flow boiling experiments in the heating configuration using liquid helium. Based on results, the new correlations show a substantial improvement over the original built-in flow boiling correlations in Thermal Desktop in predicting the wall temperature as a function of preponderant parameters for this quantum fluid at temperatures greater than the lambda temperature, T λ = 2.17K.

cryogenic propellant transfer↗

NASA NTRSDate not supplied

Simulations of Cryogenic Line Chilldown with Advanced Sub-Grid Wall Boiling Models

A meso-scale model developed at MIT [2][11] for boiling processes in water was adapted for cryogens and demonstrated for chilldown of propellant transfer lines in both liquid nitrogen and hydrogen. The sub-grid boiling model accurately captures the contributions to heat transfer from the generation of bubble nuclei, growth, and interaction of the bubbles in the microlayer as well as quenching of the boiling surface following bubble departure. It was adapted for cryogenic fluids using thermodynamic scaling concepts taking into account non-dimensional pressures and temperatures that are scaled by the corresponding critical values for the fluid. The boiling model was demonstrated for line chilldown in liquid nitrogen (Darr et al. [6]). The predicted wall temperature at which quenching occurs was close to the test data while the slope of the temperature curve after quenching is initiated, showing a steeper variation than the test data. Simulations were also performed for liquid hydrogen by simulating experiments of Hartwig et al. [7]. Chilldown times in liquid hydrogen are much more rapid due to higher heat transfer in the film boiling regime and accounting for the higher turbulence levels were found to be important. Furthermore, at the much lower fluid temperatures in liquid hydrogen flows, accounting for the variable thermal properties of the solid material is critical and has a dramatic impact on the quench times. The need for additional studies to better understand the evolution of the quench front in liquid hydrogen was noted.

Computational Fluid Dynamics↗

NASA NTRSDate not supplied

Simulations of Cryogenic Line Chilldown with Advanced Sub-Grid Wall Boiling Models

Computational Fluid Dynamics↗

NASA NTRSDate not supplied

Cryogenic Flow Boiling Parabolic Flight Experiment and Universal Correlations for Cryogens

Cryogenic fluids are employed in many industries and play crucial roles in space applications, including nuclear thermal propulsion systems, LOX/LCH4 ascent and descent stage feedlines, LOX/LH2 transfer lines for in-space fuel depots, and LHe transfer lines that cool space experiments. Due to the ultra-low boiling point of cryogens, phase change is inevitable in these systems, which leads to complex boiling behavior in reduced gravity. For cost-effective design and sizing of the aforementioned systems, accurate knowledge of two-phase parameters such as pressure drop, heat transfer coefficient (HTC), and critical heat flux (CHF) is desired. Since 2018, researchers from Purdue University and NASA Glenn Research Center (GRC) have been collaborating to investigate the effects of reduced gravity on cryogenic pool boiling, flow boiling ins tubes, and spray cooling. Using a variety of both terrestrial and parabolic flight experimental rigs, extensive LN2 data have been amassed and combined with cryogenic data from World literature to develop both ‘universal’ empirical correlations and CFD models, which are expected to serve as foundation for design of future space systems involving cryogenic fluids. This presentation will provide an overview of both the experimental work and predictive tools that have resulted from the joined Purdue-Glenn studies.

Flow Boiling↗

DOE OSTI2016

Effects of liquid subcooling and initial rod temperature on the minimum film boiling temperature

This paper presents an experimental study on the minimum film boiling temperature (T{sub min}) and its sensitivity to liquid subcooling and initial rod temperature. T{sub min} is measured through a quenching experiment using a vertical stainless steel rod that is quenched in a distilled water bath. The cylindrical stainless steel rod has a flat circular end with diameter of 9.5 mm similar to that of a fuel rod and length of 25 cm. Physically, T{sub min} is used to define the boundary between film boiling and transition boiling, beyond which temperature liquid would not be able to come into physical contact with the solid surface. Results show that the quenching curves are affected by varying the liquid subcooling but are not significantly altered by the initial rod temperature. Additionally, the experiments include visualization of the boiling regimes. The visualization gives insight into the film flow behavior that is found to depend strongly on the liquid subcooling. It also provides an understanding of the phenomenon for quench front axial propagation (authors)

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2021

Alteration of pool boiling heat transfer on metallic surfaces by in situ oxidation

The critical heat flux during pool boiling has been investigated for a range of applications including electrical power generation and thermal management. Reported experimental CHF values during pool boiling of water on flat metallic surfaces, however, show a large discrepancy across studies. Here, we address this discrepancy in CHF values by accounting for oxidation of metallic surfaces during boiling. We studied the effect of in situ oxidation on flat Cu and Ni surfaces by changing the duration that samples were held in saturated water before conducting boiling experiments. The morphology and chemical composition of surfaces after the boiling experiments were analyzed by atomic force microscopy and X-ray photoelectron spectroscopy, respectively. Cu surfaces showed gradually increasing CHF values as the duration in saturated water increased, which could be attributed to the increase in roughness due to the formation of Cu 2 O nanostructures. Conversely, Ni surfaces showed relatively stable CHF and morphology as a nearly flat layer of NiO formed, with one exception: formation of a highly wetting hydroxide, Ni(OH) 2 , on a Ni coupon held in saturated water for 24 h resulted in a uniquely high CHF value, signifying the importance of surface chemistry in addition to morphology. Finally, the fundamental mechanisms resulting in the wide spread of CHF values on metallic surfaces elucidated in this work will lead to more accurate estimation of CHF as well as a deeper mechanistic understanding of CHF values on engineered surfaces.

42 ENGINEERING↗

DOE OSTI2020

Ion irradiation effects on Cr-coated zircaloy-4 surface wettability and pool boiling critical heat flux.

The concept of coating the currently used nuclear fuel cladding (zirconium-based alloy, typically Zircaloy-4 or Zirc-4) with an oxidation preventive layer is a progressing Accident tolerant Fuel (ATF) candidate alloys. The coated Zirc-4-based alloys could be a solution to suppress undesirable fast reaction kinetics with high-temperature steam. Zirc-4 has been the most preferred cladding material in pressurized water reactors (PWRs). Chromium (Cr) based alloys as a coating material provides excellent corrosion protection and good strength and wear resistance. In this paper, we present the surface wettability measurements and pool boiling Critical Heat Flux (CHF) for Cr-coated Zirc-4 claddings pre- and post-exposure to an ion irradiation environment. The wettability measurements, including static contact angle (contact angle, θ) and average surface roughness (surface roughness, Ra), are introduced for samples of different coating thicknesses (5–30 μm thick). The coatings fabricated by the cold spray of Cr-Al particles to 10 mm × 10 mm × 1.95 mm Zirc-4 substrates. Post fabrication, a Pilgering (cold rolling) process, was applied to finalize the coating thickness and resulted in a significant reduction in surface roughness of initially fabricated rough surfaces. The process produced three distinguished samples 5-μm unpolished (as machined), 5-μm, and 30-μm polished (cold rolled). The measurements are presented for the three surfaces and bare Zirc-4 as a baseline surface. The contact angle analyses were implemented in theoretical models from the literature to predict pool boiling CHF. Pool boiling experiments were conducted to measure the pool boiling CHF values and compare them to the predicted values. Scanning Electron Microscope (SEM) images and Energy Dispersive X-ray Spectroscopy (EDS) analysis was performed to characterize the surfaces for better understanding and interpreting the results. The SEM images showed localized surface damage due to ion irradiation. No recognized change in the measured surface roughness due to ion irradiation. The contact angles of irradiated Cr-coated surfaces are consistently higher (10°) than pre-irradiated surfaces. Decreasing the Cr-coating layer thickness resulted in lower contact angle pre- and post- ion irradiation. The predicted pool boiling CHF using the Kandlikar model is in good agreement with the experimentally measured CHF values within ±12% for all samples.

36 MATERIALS SCIENCE↗

DOE OSTI2019

Pseudoplasticity and Dynamic Interfacial Tension Relaxation Effects on Nucleate Pool Boiling in Aqueous Polymeric Liquids

Nucleate pool boiling heat transfer and its ebullient dynamics in polymeric solutions at atmospheric pressure saturated conditions are experimentally investigated. Three grades of hydroxyethyl cellulose (HEC) are used, which have intrinsic viscosity in the range 5.29 ≤ [ η ] ≤ 10.31 [dl/g]. Their aqueous solutions in different concentrations, with zero-shear viscosity in the range 0.0021 ≤ η 0 ≤ 0.0118 [N∙s/m 2 ], exhibit shear-thinning rheology in varying degrees, as well as gas–liquid interfacial tension relaxation and wetting. Boiling heat transfer in solutions with constant molar concentrations of each additive, which are greater than their respective critical polymer concentration C * , is seen to have anomalous characteristics. There is degradation in the heat transfer at low heat fluxes, relative to that in the solvent, where the postnucleation bubble dynamics in the partial boiling regime is dominated by viscous resistance of the polymeric solutions. At higher heat fluxes, however, there is enhancement of boiling heat transfer due to a complex interplay of pseudoplasticity and dynamic surface tension effects. The higher frequency vapor bubbling train with high interfacial shear rates in this fully developed boiling regime tends to be influenced by increasing shear-thinning and time-dependent differential interfacial tension relaxation at the dynamic gas–liquid interfaces.

Engineering↗

DOE OSTI2016

Survey of Thermal-Fluids Evaluation and Confirmatory Experimental Validation Requirements of Accident Tolerant Cladding Concepts with Focus on Boiling Heat Transfer Characteristics

The U.S. Department of Energy Office of Nuclear Energy (DOE-NE) Advanced Fuels Campaign (AFC) is working closely with the nuclear industry to develop fuel and cladding candidates with potentially enhanced accident tolerance, also known as accident tolerant fuel (ATF). Thermal-fluids characteristics are a vital element of a holistic engineering evaluation of ATF concepts. One vital characteristic related to boiling heat transfer is the critical heat flux (CHF). CHF plays a vital role in determining safety margins during normal operation and also in the progression of potential transient or accident scenarios. This deliverable is a scoping survey of thermal-fluids evaluation and confirmatory experimental validation requirements of accident tolerant cladding concepts with a focus on boiling heat transfer characteristics. The key takeaway messages of this report are: 1. CHF prediction accuracy is important and the correlations may have significant uncertainty. 2. Surface conditions are important factors for CHF, primarily the wettability that is characterized by contact angle. Smaller contact angle indicates greater wettability, which increases the CHF. Surface roughness also impacts wettability. Results in the literature for pool boiling experiments indicate changes in CHF by up to 60% for several ATF cladding candidates. 3. The measured wettability of FeCrAl (i.e., contact angle and roughness) indicates that CHF should be investigated further through pool boiling and flow boiling experiments. 4. Initial measurements of static advancing contact angle and surface roughness indicate that FeCrAl is expected to have a higher CHF than Zircaloy. The measured contact angle of different FeCrAl alloy samples depends on oxide layer thickness and composition. The static advancing contact angle tends to decrease as the oxide layer thickness increases.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗