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DOE OSTI2013

Experimental Challenges and Successes in Measuring Aerosol Concentrations at Prototypic Spray Conditions Encountered at the Hanford Waste Treatment and Immobilization Plant - 13327

To date, majority of the work done on measuring aerosol releases from failure of process piping was done using simple Newtonian fluids and small engineered-nozzles that do not accurately represent the fluids and breaches postulated during accident analysis at the Hanford Waste Treatment and Immobilization Plant (WTP). In addition, the majority of the work conducted in this area relies on in-spray measurements that neglect the effect of splatter and do not yield any information regarding aerosol generation rates from this additional mechanism. In order to estimate aerosol generation rates as well as reduce the uncertainties in estimating the aerosol release fractions over a broad range of breaches, fluid properties and operating conditions encountered at the WTP, the Pacific Northwest National Laboratory (PNNL) has designed, commissioned, and tested two experimental test stands. The first test stand, referred to as the large-scale test stand, was designed specifically to measure aerosol concentrations and release fractions under prototypic conditions of flow and pressure for a range of breaches postulated in the hazard analysis for 0.076 m (3-inch) process pipes. However, the size of the large-scale test stand, anticipated fluid loss during a breach, experimental risks, and costs associated with hazardous chemical simulant testing limited the large-scale test stand utility to water and a few non-hazardous physical simulants that did not fully span the particle size and rheological properties of the fluids encountered at the WTP. Overcoming these limitations and extending the range of simulants used, required designing and building a smaller test stand, which was installed and operated in a fume hood. This paper presents some of the features of both test stands, the experimental challenges encountered, and successes in measuring aerosol concentration in both test stands over a range of test conditions. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2015

Experimental and numerical validation of an ultrasonic visualization system for nuclear reactor application

This paper deals with the design of ultrasonic imaging systems for the next generation of nuclear reactors cooled by liquid metal. Indeed, a generation IV research nuclear reactor is being developed by the Belgian Nuclear Research Center (SCK-CEN) in the frame of the MYRRHA project (for Multipurpose hYbrid Research Reactor for High-tech Applications). This sub-critical/critical reactor is cooled by Lead-Bismuth Eutectic (LBE). The opacity of this liquid metal requires the development of an ultrasonic visualization system for internal inspection and object detection. But due to the peculiar conditions met in the core of the reactor, velocity as well as temperature gradients are expected and are likely to affect directly the ultrasonic propagation. The objective of this work is to validate the ultrasonic imaging strategy by tests performed in a dedicated test rig and by numerical simulations using a ray-tracing method. The experimental investigations have been performed on a specific water facility reproducing conditions similar to those encountered in the core of the MYRRHA reactor. These conditions include the propagation over large distance, and the presence of temperature and velocity gradients. In the MYRRHA reactor application, the distance to be travelled by the acoustic waves of the visualization system is about 5 m, including a reflection. The acoustic absorption, the scattering losses, the beam divergence and the transmitted energy during reflection have been determined as a function of the travelled distance. The experimental values are compared with the literature for validation. The presence of temperature and velocity gradients in the core of the reactor is due to the coolant circulation. These gradients are about 5 K over 0.1 m and 1 m/s over 0.2 m, respectively, and are reproduced in the facility for investigating their influence on the propagation of ultrasounds. The experimental data are used for improving and validating a ray-tracing algorithm. This algorithm is then applied to the full scale application for validating the ultrasonic visualization system for nuclear reactor application. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2015

JHR Project: a future Material Testing Reactor working as an International user Facility: The key-role of instrumentation in support to the development of modern experimental capacity

Research and development on fuel and material behaviour under irradiation is a key issue for sustainable nuclear energy in order to meet specific needs by keeping the best level of safety. These needs mainly deal with a constant improvement of performances and safety in order to optimize the fuel cycle and hence to reach nuclear energy sustainable objectives. A sustainable nuclear energy requires a high level of performances in order to meet specific needs such as: - Pursuing improvement of the performances and safety of present and coming water cooled reactor technologies. This will require a continuous R and D support following a long-term trend driven by the plant life management, safety demonstration, flexibility and economics improvement. Experimental irradiations of structure materials are necessary to anticipate these material behaviours and will contribute to their optimisation. - Upgrading continuously nuclear fuel technology in present and future nuclear power plants to achieve better performances and to optimise the fuel cycle keeping the best level of safety. Fuel evolution for generation II, III and III+ is a key stake requiring developments, qualification tests and safety experiments to ensure the competitiveness and safety: experimental tests exploring the full range of fuel behaviour determine fuel stability limits and safety margins, as a major input for the fuel reliability analysis. To perform such accurate and innovative progress and developments, specific and ad hoc instrumentation, irradiation devices, measurement methods are necessary to be set up inside or beside the material testing reactor (MTR) core. These experiments require beforehand in situ and on line sophisticated measurements to accurately determine different key parameters such as thermal and fast neutron fluxes and nuclear heating in order to precisely monitor and control the conducted assays. The new Material Testing Reactor JHR (Jules Horowitz Reactor) currently under construction at CEA Cadarache research centre in the south of France will represent a major Research Infrastructure for scientific studies regarding material and fuel behavior under irradiation. It will also be devoted to medical isotopes production. Hence JHR will offer a real opportunity to perform R and D programs regarding needs above and hence will crucially contribute to the selection, optimization and qualification of these innovative materials and fuels. The JHR reactor objectives, principles and main characteristics associated to specific experimental devices associated to measurement techniques and methodology, their performances, their limitations and field of applications will be presented and discussed. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2015

Progress in the development of the neutron flux monitoring system of the French GEN-IV SFR: simulations and experimental validations [ANIMMA--2015-IO-392]

France has a long experience of about 50 years in designing, building and operating sodium-cooled fast reactors (SFR) such as RAPSODIE, PHENIX and SUPER PHENIX. Fast reactors feature the double capability of reducing nuclear waste and saving nuclear energy resources by burning actinides. Since this reactor type is one of those selected by the Generation IV International Forum, the French government asked, in the year 2006, CEA, namely the French Alternative Energies and Atomic Energy Commission, to lead the development of an innovative GEN-IV nuclear- fission power demonstrator. The major objective is to improve the safety and availability of an SFR. The neutron flux monitoring (NFM) system of any reactor must, in any situation, permit both reactivity control and power level monitoring from startup to full power. It also has to monitor possible changes in neutron flux distribution within the core region in order to prevent any local melting accident. The neutron detectors will have to be installed inside the reactor vessel because locations outside the vessel will suffer from severe disadvantages; radially the neutron shield that is also contained in the reactor vessel will cause unacceptable losses in neutron flux; below the core the presence of a core-catcher prevents from inserting neutron guides; and above the core the distance is too large to obtain decent neutron signals outside the vessel. Another important point is to limit the number of detectors placed in the vessel in order to alleviate their installation into the vessel. In this paper, we show that the architecture of the NFM system will rely on high-temperature fission chambers (HTFC) featuring wide-range flux monitoring capability. The definition of such a system is presented and the justifications of technological options are brought with the use of simulation and experimental results. Firstly, neutron-transport calculations allow us to propose two in-vessel regions, namely the above-core and under-core structures. We verify that they comply with the main objective, that is the neutron power and flux distribution monitoring. HTFC placed in these two regions can detect an inadvertent control rod withdrawal that is a postulated initiating event for safety demonstration. Secondly, we show that the HTFC reliability is enhanced thanks to a more robust physical design and the fact that it has been justified that the mineral insulation is insensitive to any increase in temperature. Indeed, the HTFC insulation is subject to partial discharges at high temperature when the electric field between their electrodes is greater than about 200 V/mm or so. These discharges give rise to signals similar to the neutron pulses generated by a fission chamber itself, which may bias the HTFC count rate at start-up only. However, as displayed in Figure 1, we have experimentally verified that one can discriminate neutron pulses from partial discharges using online estimation of pulse width. Thirdly, we propose to estimate the count rate of a HTFC using the third order cumulant of its signal that is described by a filtered Poisson process. For such a statistic process, it is known that any cumulant, also called cumulative moment, is proportional to the process intensity that is here the count rate of a fission chamber. One recalls that the so-called Campbelling mode of such a detector is actually based on the signal variance, which is the second-order cumulant as well. The use of this extended Campbelling mode based on the third-order cumulant will permit to ensure the HTFC response linearity over the entire neutron flux range using a signal processing technique that is simple enough to satisfy design constraints on electric devices important for nuclear safety. We also show that this technique, named high order Campbelling method (HOC), is significantly more robust than another technique based on the change in the HTFC filling gas, which consists in adding a few percent of nitrogen. Finally, we also present an experimental campaign devoted to the required calibration process of the so-called HOC method. The Campbelling results show a good agreement with the simple pulse counting estimation at low count rates. It is also shown that the HOC technique provides a linear estimation of the count rates at higher power levels as well.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2016

Experimental test plan for PWR sister rods in the high burnup spent fuel data project

The High Burnup Spent Fuel Data Project (herein referred to as the 'project'), sponsored by the US Department of Energy (DOE) Office of Nuclear Energy (NE), is focused on experimentally defining the effects of long-term storage and transportation on high burnup (HBU) pressurized water reactor (PWR) fuel (>45 gigawatt days per metric ton uranium). The goals of the project are to provide confirmatory data for model validation and potential improvement; to provide input to future dry storage cask design; to support license renewals and new licenses for Independent Spent Fuel Storage Installation facilities; and to support transportation licensing for high burnup used fuel. In support of these project goals, an instrumented TN-32B bolted-lid cask at the North Anna reactor site will be loaded with intact, HBU PWR fuel assemblies (project assemblies) having four different kinds of cladding: standard Zircaloy-4, low-tin Zircaloy-4, ZIRLO, and M5. In approximately 10 years, the instrumented cask will be opened for inspection and several fuel rods from the project assemblies will be characterized. To support the project goals, the project pulled 25 'sister rods', 9 from the project assemblies and 16 from similar HBU assemblies, for characterization. The 25 sister rods are all high burnup and cover the range of cladding alloys. The 25 sister rods were shipped to Oak Ridge National Laboratory (ORNL) in early 2016 for detailed nondestructive and destructive examination. Examinations are intended to provide baseline data on the initial physical state of the cladding and fuel prior to the loading, drying, and long-term dry storage process. Further examinations are focused on determining the effects of temperatures encountered during and following drying. Similar tests will be performed on rods taken from the project assemblies at the end of the storage period (the 'cask rods') to identify any significant changes in the fuel rods that may have occurred during the dry storage period. Additionally, some of the sister rods will be used for separate effects testing to expand the applicability of the project data to the fleet, and to address some of the data-related gaps associated with extended storage and subsequent transportation of high burnup fuel. A draft test plan is being developed that describes the experimental work to be conducted on the sister rods. This paper summarizes the draft test plan and necessary coordination activities for the multi-year experimental program to supply data relevant to the assessment of the safety of long-term storage followed by transportation of high burnup used fuel. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2016

Uncertainty evaluation for the realistic safety analysis methodology of RIA by utilizing experimental results

An audit calculation methodology for the safety analysis of reactivity-initiated accident (RIA) in a PWR based on the realistic approach is under developing in Korean Institute of Nuclear Safety. In this paper important uncertainty parameters to the rod performance were described, and the validity of those parameters was assessed by utilizing the CABRI and NSRR experimental results. Sensitivity study has been carried out to identify the parameters by changing fuel burnup, injected energy and full-width half maximum (FWHM) of given RIA power pulses. FRAPCON-3.5 and FRAPTRAN-1.5 fuel performance code were utilized. Non-parametric order statistics was used for the uncertainty quantification, and 124 inputs on each experimental case were produced by simple random sampling technique. Analysis results showed that the assessed fuel performance uncertainties such as the fuel enthalpy, fission gas release and clad plastic hoop strain could not bound some experimental results. This means that the currently considered uncertainty range, particularly for the peak power, is not enough to cover the fuel performance uncertainty within a sufficient probability and confidence level. (author)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2016

Experimental Seismic Response of Scaled Storage Containments under Identical Loading Conditions - 16318

Dry Storage Casks (DSCs) store spent nuclear fuel (SNF), usually at sites contiguous to nuclear power plants known as Independent Spent Fuel Storage Installation (ISFSI). DSCs have been considered as a temporary storage solution, and are usually licensed for 20 years, which can be extended up to an operating periods of 60 years. Recently, however, DSCs have been considered as a potential mid-term solution for hundreds of years. This consideration requires reevaluation of DSC performance under a larger seismic hazard. That leads to larger horizontal and vertical accelerations. This study is a part of a research project evaluating the seismic response of free-standing DSCs under long return period seismic events. This article assess whether the response of free-standing structures under seismic excitation is repeatable. For this purpose, experimental tests were conducted using a six degree-of-freedom (6DOF) shake table. During the experimental tests, several ground motions were repeated multiple times to obtain the dynamic response under identical loading conditions. Scaled casks of four aspect ratios (radius to centroidal height ratio, r/h{sub cg}) were studied: 0.39, 0.43, 0.55 and 0.62. The specimens studied are considered to be 1:2.5 and 1:3.5 scaled model of generic prototype casks. The experimental results show that a small change in initial conditions leads to change in the boundary condition of moving bodies and in combination with acceleration being applied at different frequencies contained within the applied ground motions may lead to a large variation in the response. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2016

The Dynamic Response of a Wire-Wrapped Pin - A New Experimental Method

There is a present desire to experimentally acquire resolved strain and deflection along long, slender cylinders using non-visible and minimally invasive instrument techniques. This desire supports present safety related activities within the nuclear power industry. At present, no relevant technology has been demonstrated to support this function while satisfying the above requirements. This study presents and details a new method for experimentally quantifying the deflection of a cylindrical experiencing both static and dynamic loads. The method applies a distributed strain fiber-optic sensor which is helically wrapped along the axial length of the pin. An analytic relation is developed herein which decomposes the helical strain into both axial strain as well as axial deflection. This newly developed experimental method is compared against analytic solutions using ideal beam theory as well as independent and proven optical methods for the purpose of verifying the new method. The outcome of this study results in a new and verified method that quantifies the axial deflection distribution of a cylindrical pin. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

SG50 Data-format Requirement Document for an Automatically Readable, Comprehensive and Curated Experimental Reaction Database MEDUSA

This report constitutes the requirement document that guides the development of the experimental reaction database, MEDUSAL (Machine-readable Experimental Data User App & Library), created by OECD/NEA/WPEC SubGroup 50. Experimental reaction data are usually stored in the EXFOR library in EXFOR format. With MEDUSAL, the WPEC sub-group 50 wants to go beyond the EXFOR format and database to generate a library that is (a) automatically readable, (b) comprehensive, and (c) curated.

Nuclear Criticality Safety Program (NCSP)↗

DOE OSTI2026

Passive Energy-Saving Solutions for Clothes Dryers: A Modeling and Experimental Study for Improved Efficiency and Affordability

Dryers are integral appliances in modern households, yet their significant power consumption remains a critical challenge for reducing energy bills and upgrades. This work presents the outcomes of a comprehensive investigation aimed at lowering the operating energy costs of the dryer through modeling and experimental approaches. Specifically, the objectives of this research are twofold: (1) to reduce energy consumption without negatively impacting drying performance or time; and (2) to ensure affordability by developing retrofittable solutions characterized by low cost and a quick payback period. These strategies promise universal applicability to all dryer categories, encompassing both gas and electric models, by tackling core issues such as unnecessary heat loss and excess energy supply, both prevalent across dryer designs. Our methodology combines robust modeling frameworks and experimental validation to target energy efficiency improvements through three primary pathways: (1) effective heat loss management using ultralow-cost insulation materials tailored for dryer systems; (2) heat management across the drying cycle, facilitated by passive heat transfer mechanisms, and (3) optimization of heat supply to the load to ensure precise energy delivery, minimizing waste. These innovations are designed to seamlessly integrate with existing dryer configurations, providing a scalable and retrofittable solution that ensures affordability without requiring substantial redesigns or expensive components. Using these methods, the study demonstrates improvement opportunities in dryer energy consumption while maintaining the desired performance. The modeling component utilizes computational simulations to evaluate the thermal and energy performance of these innovations under varied operational conditions, providing foundational insights for experimental design. By addressing critical areas such as heat loss, energy recovery, and supply optimization, this work proposes impactful solutions for lowering the energy costs in domestic clothes dryers. The ultralow-cost, retrofittable nature of the proposed strategies ensures widespread adoption potential across diverse dryer categories, making significant strides toward affordable household energy practices.

Cheekatamarla, Praveen [ORNL] (ORCID:0000000248827↗

NASA NTRS1989

An Experimental Method for Measuring Water Droplet Impingement Efficiency on Two- and Three-dimensional Bodies

An experimental method was developed to determine the droplet impingement characteristics on 2-D and 3-D bodies. The experimental results provide the essential droplet impingement data required to validate water droplet trajectory codes, which are used in the analysis of aircraft icing. A body, whose water droplet impingement characteristics are required, is covered at strategic locations by thin strips of moisture absorbing (blotter) paper, and is exposed to an air stream containing a water dye solution spray cloud. Water droplet impingement data are extracted from the dyed blotter strips by measuring the optical reflectance of the dye deposit on the strips, using an automated reflectometer. Models tested include a 4-inch diameter cylinder, a NACA 652015 airfoil section, a MS(1)-0317 supercritical airfoil section, three simulated ice shapes, an axisymmetric inlet and a Boeing 737-300 inlet model. Detailed descriptions of the dye tracer technique, instrumentation, data reduction method and the results obtained are presented. Analytical predictions of collection efficiency characteristics for most test configurations are included for comparison.

Trajectory code validation↗

DOE OSTI2022

Enabling Modular Autonomous Feedback‐Loops in Materials Science through Hierarchical Experimental Laboratory Automation and Orchestration

Abstract Materials acceleration platforms (MAPs) operate on the paradigm of integrating combinatorial synthesis, high‐throughput characterization, automatic analysis, and machine learning. Within a MAP, one or multiple autonomous feedback loops may aim to optimize materials for certain functional properties or to generate new insights. The scope of a given experiment campaign is defined by the range of experiment and analysis actions that are integrated into the experiment framework. Herein, the authors present a method for integrating many actions within a hierarchical experimental laboratory automation and orchestration (HELAO) framework. They demonstrate the capability of orchestrating distributed research instruments that can incorporate data from experiments, simulations, and databases. HELAO interfaces laboratory hardware and software distributed across several computers and operating systems for executing experiments, data analysis, provenance tracking, and autonomous planning. Parallelization is an effective approach for accelerating knowledge generation provided that multiple instruments can be effectively coordinated, which the authors demonstrate with parallel electrochemistry experiments orchestrated by HELAO. Efficient implementation of autonomous research strategies requires device sharing, asynchronous multithreading, and full integration of data management in experimental orchestration, which to the best of the authors’ knowledge, is demonstrated for the first time herein.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Experimental validation of a Kalman observer using linearized OpenFAST and a fully instrumented 1:70 model

Abstract To enable real‐time monitoring and control strategies for floating offshore wind turbines, accurate information about the state of the system is needed. This paper details the application of a Kalman filter to the UMaine VolturnUS‐S floating wind platform to provide accurate state estimates in real time using minimal system measurements. The midfidelity nonlinear simulation tool OpenFAST was used to generate the underlying linear state‐space model for the Kalman filter. This linear model and its limitations are demonstrated through comparison with experimental data collected on a 1:70 froude‐scaled model of the floating platform and tower. Using a selection of five measurements from the real system, a Kalman filter was developed to provide estimates for the remaining system states and measurements. These estimates were then validated against the experimental values collected from testing of the scale model. Validation of the Kalman filter produced accurate estimates of surge, heave, and tower base bending moment, measurements of which were not available to the Kalman filter. Performance of the Kalman filter was tested and validated over a range of sea conditions from rated wind speed to storm events and demonstrated robustness in the Kalman filter to maintain accuracy across all operating conditions despite significant error in the underlying linear model for extreme conditions.

17 WIND ENERGY↗

DOE OSTI2020

Chapter 14: Dynamic Flux Analysis: An Experimental Approach of Fluxomics

Metabolic flux analysis represents an essential perspective to understand cellular physiology and offers quantitative information to guide pathway engineering. A valuable approach for experimental elucidation of metabolic flux is dynamic flux analysis, which estimates the relative or absolute flow rates through a series of metabolic intermediates in a given pathway. It is based on kinetic isotope labeling experiments, liquid chromatography-mass spectrometry (LC-MS), and computational analysis that relate kinetic isotope trajectories of metabolites to pathway activity. Herein, we illustrate the mathematic principles underlying the dynamic flux analysis and mainly focus on describing the experimental procedures for data generation. This protocol is exemplified using cyanobacterial metabolism as an example, for which reliable labeling data for central carbon metabolites can be acquired quantitatively. This protocol is applicable to other microbial systems as well and can be readily adapted to address different metabolic processes.

BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2019

Multidimensional sum-up rounding for integer programming in optimal experimental design

Here we present a numerical method for approximating the solution of convex integer programs stemming from optimal experimental design. The statistical setup consists of a Bayesian framework for linear inverse problems for which the direct relationship is described by a discretized integral equation. Specifically, we aim to find the optimal sensor placement from a set of candidate locations where data are collected with measurement error. The convex objective function is a measure of the uncertainty, described here by the trace or log-determinant of the posterior covariance matrix, for the discretized linear inverse problem solution. The resulting convex integer program is relaxed, producing a lower bound. An upper bound is obtained by extending the sum-up rounding approach to multiple dimensions. For this extension, we analyze its accuracy as a function of the discretization mesh size for a rectangular domain. We show asymptotic optimality of the integer solution defining the upper bound for different experimental design criteria (A- and D-optimal), by proving the convergence to zero of the gap between the upper and lower bounds as the mesh size goes to zero. The technique is illustrated on a two-dimensional gravity surveying problem for both A-optimal and D-optimal sensor placement where our designs yield better results compared with a thresholding rounding approach.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2018

Giant dipole resonance parameters of ground-state photoabsorption: Experimental values with uncertainties

Updated values and corresponding uncertainties of Isovector Giant Dipole Resonance (GDR) parameters which are obtained by the least-squares fitting of theoretical photoabsorption cross sections to experimental data are presented. The theoretical photoabsorption cross sections are taken as a sum of the components corresponding to the excitation of the GDR and quasideuteron photodisintegration. The current compilation is an extension and improvement of the earlier compilations of Lorentzian parameters for ground-state photoneutron and photoabsorption cross sections and covers experimental data made available up to June 2017.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2021

Experimental validation of an organic rankine-vapor compression cooling cycle using low GWP refrigerant R1234ze(E)

There is a significant global opportunity to capture and utilize low grade waste heat to reduce fossil fuel consumption, greenhouse gas emissions, and improve energy efficiency across a wide range of industries. In this work, an advanced type of thermally activated cooling system, an organic Rankine-vapor compression cycle (ORVC) with novel heat integration strategies, was designed and tested at a relevant scale for industrial waste heat recovery (300 kW th cooling capacity). The ORVC linked an organic Rankine power cycle and a vapor compression cooling cycle using a turbine and compressor that shared a single shaft. The ORVC test facility absorbed waste heat from a liquid stream at 91 °C to simulate engine coolant in diesel generator sets, rejected heat to a glycol stream at 30 °C, and generated chilled water at 7 °C. A cooling capacity of 264 kW ± 3.5 kW was experimentally validated with a COP of 0.56 ± 0.01 during steady-state operation at the design temperatures. The thermal efficiency, accounting for pump work, of the Rankine cycle was 7.7% ± 0.22% and the COP of the vapor compression cycle was 5.25 ± 0.09. The centrifugal turbo-compressor operated at 31.5 kRPM ± 0.3 kRPM, with a turbine and compressor isentropic efficiencies of 76.7% ± 0.90% and 84.8% ± 0.54%, respectively, with near-perfect power transmission between these components. The pressure drop in the piping and heat exchangers were significantly larger than expected which had a detrimental impact on the performance of the ORVC. In addition, the condenser on the cooling cycle could not deliver the subcooling as specified from the design point modeling. Furthermore, the results from the sensitivity analysis showed that the higher condenser glycol outlet temperature had the largest impact on performance, which is consistent with other analytical models in the literature. When the ORVC simulations were updated with experimental values for isentropic efficiencies of the turbomachinery, the thermal COP was 0.66 which represents an estimate of the predicted performance if test facility limitations are overcome.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2022

Multi-scale and multi-physics analysis, design optimization, and experimental validation of heat exchangers utilizing high performance, non-round tubes

Air-to-refrigerant heat exchangers (HXs) are fundamental components in HVAC&R systems, and considerable research has been dedicated designing continually smaller, lighter, and more efficient HX designs. In recent years, researchers have leveraged advancements in Computational Fluid Dynamics (CFD), Finite Element Analysis (FEA), and optimization algorithms to consider primary tube shape and topology optimization to design highly compact, high performance HXs for a multitude of applications. In this research, we present a computationally efficient, comprehensive, multi-scale, and multi-physics analysis and optimization method for air-to-refrigerant HXs featuring automated CFD and FEA simulations and approximation-assisted optimization. This methodology was utilized to design HXs with shape-optimized, non-round tubes which outperform current state-of-the-art tube-fin HXs without compromising structural integrity. The optimal HXs were shown to deliver similar thermal performance to the baseline HXs while also achieving more than 20% reductions in airside pressure drop and core envelope volume and more than 30% reduction in internal volume. Comprehensive experimental validation of the optimization methodology was conducted through the testing of two prototypes in a standardized wind tunnel facility under multiple operating conditions. For prototype #1 under dry evaporator conditions, the predicted heat load agreed within ± 10% of measured values and the predicted airside pressure drop agreed within ± 30%, while for dehumidifying conditions, the predicted sensible and latent heat loads agreed within ± 10% and ± 20% of the measured values, respectively. For prototype #2, the predicted condenser heat load agreed within ± 3.0% of measured values, and the predicted airside pressure drop agreed within ± 27%. The acceptable agreement between simulation and experimental results for the present application highlights the flexibility of the novel optimization methodology to design next generation HXs with improved performance and reduced volume, weight, and environmental impact.

42 ENGINEERING↗