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DOE OSTI2022

ADDITIVELY MANUFACTURED SURFACE HEAT TRANSFER ENHANCEMENTS FOR THE TRANSFORMATIONAL CHALLENGE REACTOR

The Transformational Challenge Reactor (TCR) is a high-temperature gas-cooled reactor design that uses additively manufactured fuel elements. TCR fuel elements have walls made of silicon carbide and are filled with tristructural-isotropic fuel particles. These fuel elements can have radically different shapes and integrated features than existing designs due to the reduced cost for complex structures in binder jet additive manufacturing. As such, binder jet additive manufacturing enables wall surface features to be embedded that can deliver superior heat transfer performance than smooth wall designs. In this work, the authors conducted a computational fluid dynamics study to evaluate selected wall features integrated into TCR fuel elements. Results show that surface features can outperform smooth wall designs; however, there are unique challenges for gas-cooled reactor core designs that have not been fully explored by previous research. For example, the rough surface finish and process variability of ceramics additive manufacturing make it challenging to predict surface roughness effects before fabrication. Additionally, the small hydraulic diameters of coolant channels in reactor cores make it difficult to engineer surface features that do not significantly increase the pressure drop. Engineers must carefully size surface features for heat transfer enhancement in additive fuel elements to operate above the base material's surface roughness effects and below the coolant channel size.

Weinmeister, Justin↗

DOE OSTI2023

Scalable simulation of coupled adsorption and transport of methane in confined complex porous media with density preconditioning

The growing significance of shales and tight formations in the transition to less carbon-intensive and clean energy drives the research endeavor to understand the physics of gas flow within these systems. However, shales are composed of massively heterogeneous physical and chemical features. Most nano-sized pores connect to millimeter-scale fractures, leading to multiscale transport. These nano-scale pore throats demonstrate non-classical flow behavior, such as non-negligible slip velocities and adsorbed gas layers at the boundary. As a result, classical computational fluid dynamics models do not capture the physics. In this work, we develop a coupling scheme for the multiple-relaxation-time (MRT) lattice Boltzmann (LB) method that integrates the Peng-Robinson equation of state into a pseudo-potential interaction model to capture the physics of methane flow in irregular networks of channels that represent nano-scale porous media. We use atomistic simulations to calibrate and validate our model in slit nano-channels. We propose a preconditioning scheme to initialize the coupled transport and adsorption simulation of methane in complex porous media. The results of this implementation of LB agree with Direct Simulation Monte Carlo (DSMC) and Molecular Dynamics (MD) simulations. We then scale up the LB implementation through vectorization and indirect addressing. We parallelize it using Message Passing Interface (MPI) and OpenMP frameworks to simulate transport and adsorption in complex media with a million lattices. Additionally, we analyze the differences between coupled and transport-only simulations in two case studies and show that considering phase behavior, i.e., adsorption, can significantly change the flow behavior. This work constitutes an important step towards bridging the gap between molecular flow and system-scale behavior of complex disordered porous media.

42 ENGINEERING↗

NASA NTRS2011

Sensor for Direct Measurement of the Boundary Shear Stress in Fluid Flow

The formation of scour patterns at bridge piers is driven by the forces at the boundary of the water flow. In most experimental scour studies, indirect processes have been applied to estimate the shear and normal stress using measured velocity profiles. The estimations are based on theoretical models and associated assumptions. However, the turbulence flow fields and boundary layer in the pier-scour region are very complex. In addition, available turbulence models cannot account accurately for the bed roughness effect. Direct measurement of the boundary shear and normal stress and their fluctuations are attractive alternatives. However, this approach is a challenging one especially for high spatial resolution and high fidelity measurements. The authors designed and fabricated a prototype miniature shear stress sensor including an EDM machined floating plate and a high-resolution laser optical encoder. Tests were performed both in air as well as operation in water with controlled flow. The sensor sensitivity, stability and signal-to-noise level were measured and evaluated. The detailed test results and a discussion of future work will be presented in this paper.

sheer stress↗

NASA NTRS2011

Sensor for Direct Measurement of the Boundary Shear Stress in Fluid Flow

shear stress↗

NASA NTRS2011

Modeling Powered Aerodynamics for the Orion Launch Abort Vehicle Aerodynamic Database

Modeling the aerodynamics of the Orion Launch Abort Vehicle (LAV) has presented many technical challenges to the developers of the Orion aerodynamic database. During a launch abort event, the aerodynamic environment around the LAV is very complex as multiple solid rocket plumes interact with each other and the vehicle. It is further complicated by vehicle separation events such as between the LAV and the launch vehicle stack or between the launch abort tower and the crew module. The aerodynamic database for the LAV was developed mainly from wind tunnel tests involving powered jet simulations of the rocket exhaust plumes, supported by computational fluid dynamic simulations. However, limitations in both methods have made it difficult to properly capture the aerodynamics of the LAV in experimental and numerical simulations. These limitations have also influenced decisions regarding the modeling and structure of the aerodynamic database for the LAV and led to compromises and creative solutions. Two database modeling approaches are presented in this paper (incremental aerodynamics and total aerodynamics), with examples showing strengths and weaknesses of each approach. In addition, the unique problems presented to the database developers by the large data space required for modeling a launch abort event illustrate the complexities of working with multi-dimensional data.

Chan, David T.↗

DOE OSTI2020

Dam-Break Flow Measurements of Liquid–Granular Mixtures in a Channelized Reservoir

Dam-break flows of granular materials exhibit a complex non-Newtonian rheology, which is strongly influenced by various factors, such as the characteristics of the granular material, the degree of initial compaction, and saturation level of the granular matrix. Specially adapted nonintrusive techniques are required to investigate these flows in the laboratory. This paper investigated the nonintrusive technique of image analysis. The methodologies used in the measurement of bulk flow parameters, such as flow depth, front velocity, and flow rate, and the extraction of detailed flow characteristics such as velocity profiles, were discussed in the context of a series of granular dam-break flow experiments. These experiments were performed under three types of initial conditions: dry, saturated (water filling the pore space), and submerged (a layer of saturated granular material submerged under water) using four types of granular materials—PET pellets, crushed walnut shells, urea, and sand—with grain sizes ranging from 200 μm to 2.9 mm. High-speed cameras were used to capture the evolution and local properties of the flow, such as velocity fields using particle image velocimetry (PIV). Bulk properties of the flow were obtained by tracking the surface profile of the granular matrix and the water table. The extracted profiles were used to measure the evolution of the volume of the granular matrix and the fluid phase separately upstream and downstream of the gate, which allowed measuring the dilatancy (increase in pore space). The study showed that the image analysis techniques are versatile and can be adapted to measure different flow parameters in a variety of granular flows to better understand and analyze their complex behavior. Finally, the advantages and drawbacks of each image analysis technique were discussed and best-practice recommendations were provided.

42 ENGINEERING↗

DOE OSTI2026

Revisiting the validity of eddy viscosity models for predicting airflow over water waves

In this study, we revisit the validity of eddy viscosity models for predicting wave-induced airflow disturbances over ocean surface waves. We first derive a turbulence curvilinear model for the phase-averaged Navier–Stokes equations, extending the work of Cao, Deng & Shen (2020 J. Fluid Mech. 901, A27), by incorporating turbulence stress terms previously neglected in the linearised viscous curvilinear model. To verify our formulation, we perform a priori tests by numerically solving the model using mean wind and turbulence stress profiles from large-eddy simulations (LES) of airflow over waves across various wave ages. Results show that including turbulence stress terms improves wave-induced airflow predictions compared with the previous viscous curvilinear model. We further show that using a standard mixing-length eddy viscosity yields inaccurate predictions at certain wave ages, as it fails to capture wave-induced turbulence, which fundamentally differs from mean shear-driven turbulence. The LES data show that accurate representations of wave-induced stresses require a complex-valued eddy viscosity. The maximum magnitude of this eddy viscosity scales as ∼𝑢 𝜏 ⁢𝜁 𝑖𝑛𝑛𝑒𝑟 , where 𝑢 𝜏 is the friction velocity and 𝜁 𝑖𝑛𝑛𝑒𝑟 is the inner-layer thickness, the height at which the eddy-turnover time matches the wave advection time scale. This scaling aligns with the prediction by Belcher & Hunt (1993 J. Fluid Mech. 251, 109–148). Overall, the findings demonstrate that traditional eddy viscosity models are inadequate for capturing wave-induced turbulence. More sophisticated turbulence models are essential for the accurate prediction of airflow disturbances and form drag in wind–wave interaction models.

16 TIDAL AND WAVE POWER↗

DOE OSTI2022

Well–based monitoring of CO 2 geological sequestration operations in saline aquifers: Critical insights into key questions

Geological carbon sequestration in saline aquifers is one of the most promising strategies to help mitigate emissions of CO 2 to the atmosphere. Significant challenges in ensuring the security of the sequestration process rest in the evolution and expansion of the CO 2 plume in the subsurface. The ability to track the movement of the injected CO 2 poses another challenge. Critical questions related to the integrity of the sequestration operations in saline aquifers relate to plume characteristics that can we monitor using well-based variables. We addressed this and related questions using an integrated modeling framework through a numerical investigation of carbon sequestration in saline aquifers during long-term and post-injection periods. This modeling paradigm incorporates the effect of structural, geological, and petrophysical characteristics. That way, we can account for critical physicochemical processes, rock-fluid interactions, and lithology dependencies. The well fluid variables investigated include fluid composition, pH, fluid density, and ion activity. We learned that fluid property analytics and diagnostics can be powerful tools to estimate the movement of CO 2 and its storage in different trapping mechanisms. These analytics can help optimize operational aspects and simplify reservoir-scale models while still reflecting the complex nature of the CO 2 interactions underground and offering insights into plume evolution.

58 GEOSCIENCES↗

DOE OSTI2025

Hydromechanical Modeling of Fault Rupture in Geologic CO 2 Sequestration: A Comparison of Two Failure Criteria

Abstract The large‐scale implementation of geological carbon sequestration has raised concerns about potential fault activation and induced seismicity, which could compromise storage integrity and pose seismic risks. We theoretically compared two failure criteria, Mohr‐Coulomb (MC) and Modified Cam‐Clay criteria (MCC), to assess fault rupture during CO 2 storage. Both criteria characterize fault behavior in a specific stress regime but differ in reducing the complexity of fault rupture to a few key mechanisms. Using a coupled hydromechanical model, we demonstrate that the choice of a failure criterion and the physics of fault weakening associated with these criteria strongly condition fault response to a given fluid injection. MC mainly relates rupture to friction, while MCC relates rupture to fault poro‐plasticity. Our findings highlight that the selection of a failure criterion, being inherently subjective, can significantly alter the predicted fault behavior during CO 2 storage, thereby impacting the reliability of geomechanical risk assessments.

Cao, M. [Energy Geosciences Division Lawrence Berk↗

NASA NTRS1974

Analytical model for liquid rocket propellant feedline dynamics

A generalized analytical model and computer program have been developed to predict the frequency response of arbitrary liquid propellant feedline designs. The analytical model is based on an extension of an existing distributed parameter representation of a viscous fluid transmission line with laminar flow which was modified to include the effects of a turbulent mean flow. The effects of dissolved ullage gases, wall elasticity, localized gas or vapor bubbles, bellows, forced changes in length due to structural excitation, complex side branches, and structural mounting stiffness are also included. Each line component is written as a four-terminal, pressure-flow relationship in matrix form in the Laplace domain; the transfer function relating the pressure response at the line terminal (inducer inlet) to the external excitation is obtained in the computer program by sequential matrix substitution.

Holster, J. L.↗

NASA NTRS1994

Optimal active control for Burgers equations

A method for active fluid flow control based on control theory is discussed. Dynamic programming and fixed point successive approximations are used to accommodate the nonlinear control problem. The long-term goal of this project is to establish an effective method applicable to complex flows such as turbulence and jets. However, in this report, the method is applied to stochastic Burgers equation as an intermediate step towards this goal. Numerical results are compared with those obtained by gradient search methods.

Ikeda, Yutaka↗

NASA NTRS2012

Modeling of Heat Transfer and Ablation of Refractory Material Due to Rocket Plume Impingement

CR Tech's Thermal Desktop-SINDA/FLUINT software was used in the thermal analysis of a flame deflector design for Launch Complex 39B at Kennedy Space Center, Florida. The analysis of the flame deflector takes into account heat transfer due to plume impingement from expected vehicles to be launched at KSC. The heat flux from the plume was computed using computational fluid dynamics provided by Ames Research Center in Moffet Field, California. The results from the CFD solutions were mapped onto a 3-D Thermal Desktop model of the flame deflector using the boundary condition mapping capabilities in Thermal Desktop. The ablation subroutine in SINDA/FLUINT was then used to model the ablation of the refractory material.

Harris, Michael F.↗

DOE OSTI2023

Predicting Wind Loading and Instability in Solar Tracking PV Arrays

Wind loading and the fluctuating pressure loads it creates on PV panel surfaces are associated with multiple degradation mechanisms and failures. Modest wind speeds create reversing loads that can initiate cell cracks and weather cracked cells. Stronger wind speeds and extreme weather events can lead to larger scale forces and the aerodynamic instability known as torsional galloping. All these effects are dependent on the complex coupling between wind speed, panel orientation, and a myriad of other hardware and site-specific factors. In this work, we present the latest developments from our work to build an open-source, high-performance computing (HPC) fluid dynamics solver to predict and mitigate these effects. This simulation package allows users to easily specify different array layouts, solar-tracking angles, panel geometries, and weather conditions before automatically generating a refined computational mesh and solving for the unsteady loading on each panel surface. Small domains (e.g., a single panel row in isolation) can be solved on a modern laptop, while larger domains or very high-fidelity studies can be solved on distributed or HPC resources with minimal modifications to the underlying problem specification. We present preliminary case studies obtained using this simulation package and highlight how increased wind speeds combined with sub-optimal tracking angles can exacerbate degradation drivers.

aerodynamics↗

DOE OSTI2023

Thermal Extraction and Delivery from Advanced Reactor Systems

This document presents preliminary thermodynamic analysis of thermal extraction and delivery from advanced nuclear reactors. Light-water, high temperature gas, sodium fast, and molten salt reactors are templated and analyzed for thermal extraction from nominal steam production conditions. Uncontrolled, controlled, and partial admission steam extraction methods are described and analyzed to show the differences in system impact from the various methods. Thermal delivery modeling results show comparisons that have become possible through the computational capabilities of the thermal delivery model. Due to the significant degrees of freedom of the problem, specific cases are used to compare the thermodynamic costs of heat transport using various heat transfer fluids. All this work is done using Modelica models, allowing for the future application of models in dynamic analyses beyond the steady-state calculations presented in this report. Appendices describe additional capabilities and methods that can help users analyze complex problems using HYBRID models developed in Modelica.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

NASA NTRS1999

Fluid Physical and Transport Phenomena Studies aboard the International Space Station: Planned Experiments

This paper provides an overview of the microgravity fluid physics and transport phenomena experiments planned for the International Spare Station. NASA's Office of Life and Microgravity Science and Applications has established a world-class research program in fluid physics and transport phenomena. This program combines the vast expertise of the world research community with NASA's unique microgravity facilities with the objectives of gaining new insight into fluid phenomena by removing the confounding effect of gravity. Due to its criticality to many terrestrial and space-based processes and phenomena, fluid physics and transport phenomena play a central role in the NASA's Microgravity Program. Through widely publicized research announcement and well established peer-reviews, the program has been able to attract a number of world-class researchers and acquired a critical mass of investigations that is now adding rapidly to this field. Currently there arc a total of 106 ground-based and 20 candidate flight principal investigators conducting research in four major thrust areas in the program: complex flows, multiphase flow and phase change, interfacial phenomena, and dynamics and instabilities. The International Space Station (ISS) to be launched in 1998, provides the microgravity research community with a unprecedented opportunity to conduct long-duration microgravity experiments which can be controlled and operated from the Principal Investigators' own laboratory. Frequent planned shuttle flights to the Station will provide opportunities to conduct many more experiments than were previously possible. NASA Lewis Research Center is in the process of designing a Fluids and Combustion Facility (FCF) to be located in the Laboratory Module of the ISS that will not only accommodate multiple users but, allow a broad range of fluid physics and transport phenomena experiments to be conducted in a cost effective manner.

Singh, Bhim S.↗

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 OSTI2020

Multiphase Reacting Flow Simulations and Optimization of Commercial-Scale Aerobic Bioreactors

Aerobic bioreactors are widely used in the synthesis of value-added products in pharmaceutical and biotechnology industries, wherein microbial bioreactions aid in the conversion of sugars to macromolecules. These reactors are also being actively investigated as a cost-effective pathway for the production of low-value commodities such as biofuels and animal feed. Reactor scale-up is one of the important challenges when designing these systems. Gas and liquid phase transport, mass-transfer, and mixing physics at large length scales can significantly affect microbial conversion rates, particularly when the microbial reaction requires a narrow set of conditions. These phenomena are difficult to study in small-scale bench-top reactors that are typically well-mixed. Predictive computational fluid dynamics (CFD) based simulations can therefore aid in the design and optimization of these reactors. This work presents multiphase Euler-Euler CFD simulations of commercial-scale (~ 500 m3) aerobic bioreactors. Our mathematical model treats the gas and liquid as interpenetrating phases. This approach reduces the computational complexity of tracking individual gas bubbles that are several orders of magnitude smaller than reactor dimensions. We solve the Reynolds averaged Navier-Stokes (RANS) multiphase equations that account for phase and chemical species transport, interphase mass and momentum transfer and uses a phenomenological model for oxygen uptake by microbes. We use a customized solver derived from open-source CFD toolbox, OpenFOAM, to perform these simulations, which has been validated against small-scale reactors in our previous work. This work examines the performance of three different reactor designs, viz. bubble column reactor, airlift reactor with an internal draft tube, and a stirred-tank reactor with Rushton impellers. Reactor oxygen mass-transfer coefficient, gas hold-up, and oxygen distribution are critically analyzed among reactors, and sensitivity studies pertaining to gas flow rates and reactor geometry will be presented.

09 BIOMASS FUELS↗

DOE OSTI2024

Efficient data-driven models for prediction and optimization of geothermal power plant operations

Increasing the capacity of geothermal energy as a renewable resource calls for development and deployment of efficient control and optimization technologies for geothermal power plants. A data-driven prediction and optimization model is presented as a cost-effective and efficient alternative to physics-based approach. The model predicts power output and operational cost by propagating the influence of control and disturbance variables within an artificial neural network (ANN). Numerical experiments with simulated and field data from a real geothermal power plant are first used to demonstrate the prediction performance of the ANN model. The model is then adopted to maximize the net predicted power production by automatically adjusting the working fluid circulation rate. The optimization performance of the model in evaluated using a thermodynamic flowsheet simulation model. The workflow is applied to model and control the effect of ambient temperature on an air-cooled binary cycle power plant, which is complex and costly to perform using a physics-based predictive model. As a result, the performance of the method is demonstrated by applying it to both simulated and field datasets from a binary cycle geothermal power plant.

15 GEOTHERMAL ENERGY↗