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At least 1,423 records · Page 79
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Effect of micro-fin tube geometry parameters on evaporator material savings

A Performance Evaluation Criteria (PEC) analysis is presented that explores the influence of the micro-fin tube geometry on the required material volume. The analysis was done using a local flow boiling model, which can quantify the effect of fin parameters and the tube diameter. The PEC was done while requiring that the compared surfaces satisfy the same heat duty and pressure drop. The following tube parameters and ranges were explored: tube diameter (3 mm ≤ D o ≤ 6 mm), fin base thickness (0.12 mm ≤ t bf ≤ 0.29 mm), helix angle (6° ≤ α ≤ 30°), fin apex angle (11° ≤ β ≤ 22°), total number of fins (43 ≤ n f ≤ 70), and the fin height (0.11 mm ≤ e ≤ 0.3 mm). The tube that provided the smallest material requirements within the examined parameter ranges had: D o = 3 mm, t bf = 0.12 mm, α = 6°, β = 11°, n f = 43, and e = 0.3 mm. In general, small D o and t bf and large n f and e provided the best performance and work to minimize the required material volume to provide a given heat duty and pressure drop. The helix and the fin-tip apex angles were found to have very little influence on the performance for the examined range of parameters and angles associated with the lowest production cost should be chosen.

Evaporation↗
DOE OSTI2024

The role of annealing and grain boundary controls on the mechanical properties of limestones and marbles

Chemical and mechanical processes are coupled in many geological and geochemical environments. Reactive processes anneal defects and restructure grain boundaries, modifying their elastic properties, levels of internal friction, wave propagation rates and fracture behaviors. The nature of these changes is, however, contingent on the initial state of the rock. Here, in this study, impulse excitation was used to measure changes in mechanical properties as a function of dry and steam heating time at 300 °C for three carbonate rocks: Carrara marble, Carthage marble (Burlington Limestone), and Texas Cream limestone (Edwards limestone), with initial porosities of about 1 %, 3 %, and 27 %, respectively. Frequency-dependent phenomena along with mineral recrystallization were observed. This was coupled with small-angle X-ray and neutron scattering analysis to determine the relationship between changes in bulk mechanical and microstructural properties. An observed decrease in both the Young's and shear moduli in the experimental limestones as a function of heating time reflects and quantifies a reduction in the stiffness of the rock due to annealing. The internal friction of the samples first increases then decreases with reaction time, reflecting defect annealing, but this was balanced against grain boundary dissolution apparently driven by condensation of steam in the confined grain-boundary environment. This suggests an increase in the boiling point under confinement leading to dissolution, increased porosity and widening of the grain boundaries. In addition, comparison of small-angle X-ray and neutron scattering results suggests that it is inappropriate to assume that pores are empty for quantitative analysis of typical small-angle scattering samples.

58 GEOSCIENCES↗
DOE OSTI2016

Fractional condensation of pyrolysis vapors produced from Nordic feedstocks in cyclone pyrolysis

Pyrolysis oil is a complex mixture of different chemical compounds with a wide range of molecular weights and boiling points. Due to its complexity, an efficient fractionation of the oil may be a more promising approach of producing liquid fuels and chemicals than treating the whole oil. In this work a sampling system based on fractional condensation was attached to a cyclone pyrolysis pilot plant to enable separation of the produced pyrolysis vapors into five oil fractions. The sampling system was composed of cyclonic condensers and coalescing filters arranged in series. Our objective was to characterize the oil fractions produced from three different Nordic feedstocks and suggest possible applications. The oil fractions were thoroughly characterized using several analytical techniques including water content; elemental composition; heating value, and chemical compound group analysis using solvent fractionation, quantitative 13 C NMR and 1 H NMR and GC x GC - TOFMS. The results show that the oil fractions significantly differ from each other both in chemical and physical properties. The first fractions and the fraction composed of aerosols were highly viscous and contained larger energy-rich compounds of mainly lignin-derived material. The middle fraction contained medium-size compounds with relatively high concentration of water, sugars, alcohols, hydrocarbonyls and acids and finally the last fraction contained smaller molecules such as water, aldehydes, ketones and acids. But, the properties of the respective fractions seem independent on the studied feedstock types, i.e. the respective fractions produced from different feedstock are rather similar. Furthermore, this promotes the possibility to vary the feedstock depending on availability while retaining the oil properties. Possible applications of the five fractions vary from oil for combustion and extraction of the pyrolytic lignin in the early fractions to extraction of sugars from the early and middle fractions, and extraction of acids and aldehydes in the later fractions.

09 BIOMASS FUELS↗
DOE OSTI2024

Comparison of atmospheric radionuclide dispersion models for a risk-informed consequence-driven advanced reactor licensing framework

Current nuclear facility emergency planning zones (EPZs) are based on outdated distance-based criteria, predating comprehensive dose and risk-informed frameworks. Recent advancements in simulation tools have permitted the development of site-specific, dose, and risk-based consequence-driven assessment frameworks. This study investigated the computation of advanced reactor (AR) EPZs using two atmospheric dispersion models: a straight-line Gaussian plume model (GPM) and a semi-Lagrangian Particle in Cell (PIC). Two case studies were conducted: (1) benchmarking the NRC SOARCA study for the Peach Bottom Nuclear Generating Station and (2) analyzing an advanced INL Heat Pipe Design A microreactor's end-of-cycle inventory. The dose criteria for both cases were 10 mSv at mean weather conditions and 50 mSv at 95th percentile weather conditions at 96 h post-release. Results demonstrated that GPM and PIC estimated similar mean peak dose levels for large boiling water reactors in the farfield case, placing EPZ limits beyond current regulations. For ARs with source terms remaining in the nearfield, PIC modeling without specific nearfield considerations could result in excessively high doses and inaccurate EPZ designations. PIC dispersion demonstrated an order of magnitude higher estimate of nearfield inhalation dose contribution when compared to GPM results. Furthermore, both models significantly reduced EPZ sizing within the nearfield. Thus, reductions in the AR source term may eliminate the need for a separate EPZ.

63 RADIATION, THERMAL, AND OTHER ENVIRON. POLLUTAN↗
DOE OSTI2014

Separation of metallic residues from the dissolution of a high-burnup BWR fuel using nitrogen trifluoride

Nitrogen trifluoride (NF 3 ) was used to fluorinate the metallic residue from the dissolution of a high burnup, boiling water reactor fuel (~70 MWd/kgU). The metallic residue included the noble metal phase (containing ruthenium, rhodium, palladium, technetium, and molybdenum), and smaller amounts of zirconium, selenium, tellurium, and silver. Exposing the noble metal phase to 10% NF 3 in argon between 400 and 550°C, removed molybdenum and technetium near 400°C as their volatile fluorides, and ruthenium near 500C as its volatile fluoride. The events were thermally and temporally distinct and the conditions specified are a recipe to separate these transition metals from each other and from the noble metal phase nonvolatile residue. Depletion of the volatile fluorides resulted in substantial exothermicity. Thermal excursion behavior was recorded under non-adiabatic, isothermal conditions that typically minimize heat release. Physical characterization of the metallic noble phase and its thermal behavior are consistent with high kinetic velocity reactions encouraged by the nanoparticulate phase or perhaps catalytic influences of the mixed platinum metals with nearly pure phase structure. Post-fluorination, only two phases were present in the residual nonvolatile fraction. These were identified as a nano-crystalline, metallic palladium cubic phase and a hexagonal rhodium trifluoride (RhF 3 ) phase. The two phases were distinct as the sub-µm crystallites of metallic palladium were in contrast to the RhF 3 phase, which grew from the parent nano-crystalline noble-metal phase during fluorination, to acicular crystals exceeding 20-µm in length.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Fuel property evaluation of unique fatty acid methyl esters containing β-hydroxy esters from engineered microorganisms

Unique fatty acid methyl esters (FAME) containing ..beta..-hydroxy esters were produced using an engineered microorganism by glucose fermentation. This study investigated the properties of the unique FAME mixture both neat and in blends with conventional diesel, as well as properties of ..beta..-hydroxy esters. The unique FAME blend contained relatively shorter-chain FAME (average fatty acid chain carbon number 14.6) with 58 % monounsaturated fatty acids and 9 % saturated and monounsaturated ..beta..-hydroxy acid chains. The unique FAME had significantly lower distillation T90 (321 °C versus 352 °C) and higher cetane number (56.7 versus 52) compared to soy biodiesel. Cloud points were within method repeatability. Unexpectedly (because of the lack of methylene-interrupted double bonds), the unique FAME had low oxidation stability (1.5 h) as determined by Rancimat induction period. Stability could be improved through addition of commonly used antioxidants. We speculate that monounsaturated ..beta..-hydroxy FAME may be the source of this instability. Blends with conventional diesel up to 50 vol% showed similar kinematic viscosity (within method repeatability) as blends of conventional FAME. The unique FAME had no effect on distillation T90 even at the 80% blend level. A 30 vol% blend into conventional diesel had a Rancimat induction period of only 2 h, very nearly the same as the neat unique FAME sample. The addition of antioxidants produced blends of acceptable stability. Based on an assessment of the properties of individual ..beta..-hydroxy FAME molecules, they have higher boiling point, higher cloud point, lower cetane number, and potentially lower storage stability than analogous FAME not having the ..beta..-hydroxy group. Removing them from the fuel product in the production process may result in a biodiesel product with superior properties to what is on the market today.

09 BIOMASS FUELS↗
DOE OSTI2020

Manufacturing Process Design of a Micro-Scale Liquid-Liquid Extractor and Multi-phase Separator

Advances in process innovation within the chemical process industry are impeded by the cost of producing new innovative components. In this paper, various manufacturing process routes were evaluated for scaling up a micro-scale liquid-liquid extractor and multi-phase separator capable of separating immiscible phases that are used for the extraction of a chemical product into a lower boiling point solvent to make downstream distillation easier. A manufacturing process design methodology was used to evaluate both photochemical machining and binder jetting as a means for producing the micropost arrays within the separator. Cost curves show that for a 0.3 mm deep micropost array, photochemical machining was found to be much cheaper than binder jetting. However, because binder jetting processes enable microposts with over 13 times higher depth-to-width aspect ratios, binder jetting was found to decrease the overall costs of the extractor/separator by more than half for a 500 barrel per day plant, with breakeven as low as 15 barrels per day. These economics were confirmed by building extractor/separator plates and characterizing them dimensionally and functionally. The binder jet plates were found to perform better than photochemical plates leading to the complete separation of the organic phase from water. The utilization of slower sintering cycles combined with surface grinding provided acceptable dimensional tolerances for the binder jet plates. Using pressurized air during depowdering improved the economics for the binder jetting process.

42 ENGINEERING↗
DOE OSTI2021

Determining processing behaviour of pure Cu in laser powder bed fusion using direct micro-calorimetry

We report copper is challenging to process by laser powder bed fusion (LPBF) given its high reflectivity at common infrared laser diode wavelengths and high thermal conductivity. Successful deposition of copper in a predictable and repeatable fashion relies on understanding the development of the keyhole melting regime, as well as heating, melting, boiling and vapour formation behaviour when interacting with a laser beam within an LPBF environment. In this study, in situ optical absorptivity measurements are used to clarify the complex physics of the laser material interaction. Absorptivity of laser energy is measured using direct micro-calorimetry and compared to melt pool depth in correlation to processing parameters. The measured absorptivity for a 100 μm layer thickness of powder was found to be approximately four times higher than that of the bare polished discs. It was also shown that high laser power above 500 W and scan speed up to 150 mm/s are appropriate for effective melting of the powder layer, with these parameters overcoming the threshold required to achieve keyhole melting. This is explained by multiple reflections withing the powder particles and the lower thermal conductivity of packed powder in comparison to bare discs. Melt pool formation was found to be highly unstable and an explosive behavior was observed when in the keyhole regime, caused by high fluctuations in absorptivity values. This work demonstrates calorimetry can be used to monitor melting behaviour in a real-time fashion during processing for this challenging to process material, thereby avoiding unnecessary parametric optimisation. In addition, the parametric window for optimum processing revealed here can inform future work.

36 MATERIALS SCIENCE↗
DOE OSTI2014

Ultra-High Temperature Steam Corrosion of Complex Silicates for Nuclear Applications: A Computational Study

Stability of materials under extreme conditions is an important issue for safety of nuclear reactors. Presently, silicon carbide (SiC) is being studied as a cladding material candidate for fuel rods in boiling-water and pressurized water-cooled reactors (BWRs and PWRs) that would substitute or modify traditional zircaloy materials. The rate of corrosion of the SiC ceramics in hot vapor environment (up to 2200 degrees C) simulating emergency conditions of light water reactor (LWR) depends on many environmental factors such as pressure, temperature, viscosity, and surface quality. Using the paralinear oxidation theory developed for ceramics in the combustion reactor environment, we estimated the corrosion rate of SiC ceramics under the conditions representing a significant power excursion in a LWR. It was established that a significant time – at least 100 h – is required for a typical SiC braiding to significantly degrade even in the most aggressive vapor environment (with temperatures up to 2200 °C) which is possible in a LWR at emergency condition. This provides evidence in favor of using the SiC coatings/braidings for additional protection of nuclear reactor rods against off-normal material degradation during power excursions or LOCA incidents. Additionally, we discuss possibilities of using other silica based ceramics in order to find materials with even higher corrosion resistance than SiC. In particular, we found that zircon (ZrSiO4) is also a very promising material for nuclear applications. Thermodynamic and first-principles atomic-scale calculations provide evidence of zircon thermodynamic stability in aggressive environments at least up to 1535 degrees C.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2016

Uniform corrosion of FeCrAl alloys in LWR coolant environments

The corrosion behavior of commercial and model FeCrAl alloys and type 310 stainless steel was examined by autoclave tests and compared to Zircaloy-4, the reference cladding materials in light water reactors. The corrosion studies were carried out in three distinct water chemistry environments found in pressurized and boiling water reactor primary coolant loop conditions for up to one year. The structure and morphology of the oxides formed on the surface of these alloys was consistent with thermodynamic predictions. Spinel-type oxides were found to be present after hydrogen water chemistry exposures, while the oxygenated water tests resulted in the formation of very thin and protective hematite-type oxides. Unlike the alloys exposed to oxygenated water tests, the alloys tested in hydrogen water chemistry conditions experienced mass loss as a function of time. This mass loss was the result of net sum of mass gain due to parabolic oxidation and mass loss due to dissolution that also exhibits parabolic kinetics. Finally, the maximum thickness loss after one year of LWR water corrosion in the absence of irradiation was ~2 μm, which is inconsequential for a ~300–500 μm thick cladding.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Hydrothermal corrosion of silicon carbide joints without radiation

In this paper, hydrothermal corrosion of four types of the silicon carbide (SiC) to SiC plate joints were investigated under pressurized water reactor and boiling water reactor relevant chemical conditions without irradiation. The joints were formed by metal diffusion bonding using molybdenum or titanium interlayer, reaction sintering using Ti—Si—C system, and SiC nanopowder sintering. Most of the joints withstood the corrosion tests for five weeks. The recession of the SiC substrates was limited. Based on the recession of the bonding layers, it was concluded that all the joints except for the molybdenum diffusion bond are promising under the reducing environments without radiation. Finally, the SiC nanopowder sintered joint was the most corrosion tolerant under the oxidizing environment among the four joints.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Hydrothermal corrosion of 2nd generation FeCrAl alloys for accident tolerant fuel cladding

As part of an effort to develop advanced fuel cladding for use in light water reactors, several FeCrAl alloys have been developed at Oak Ridge National Laboratory. A second generation of these alloys bearing additional alloying elements over the previously tested model alloys were tested in boiling water reactor (BWR) conditions to determine their resistance to hydrothermal corrosion. Coupons with alloy compositions Fe–10Cr–6Al–2Mo, Fe–13Cr–5Al–2Mo, Fe–13Cr–6Al–2Mo, Fe–13Cr–7Al–2Mo, and Fe–13Cr–5Al–2Mo–1Nb were tested in normal water chemistry (NWC) and hydrogen water chemistry (HWC) for 9 months in continuously refreshing autoclaves. Commercial FeCrAl alloy APMT and Zircaloy-2 were also tested for comparison. Among samples exposed to HWC, Fe–13Cr–7Al–2Mo performed worst with an average mass loss of 1.3 mg/cm2 over 9 months. This mass loss represents an estimated thickness loss of approximately 60 μm over 6 years. Samples exposed to NWC had very small mass losses of less than 0.15 mg/cm2 or mass gains up to 0.05 mg/cm2. Based on the results of this testing, the 2nd generation FeCrAl alloys tested exhibit low wall thickness loss and are suitable in terms of corrosion resistance for use as LWR cladding in BWR-HWC and BWR-NWC under normal operating conditions.

Raiman, Stephen↗
DOE OSTI2020

Burst behavior of nuclear grade FeCrAl and Zircaloy-2 fuel cladding under simulated cyclic dryout conditions

A novel experiment to simulate cyclic dryout in boiling water reactors has been developed to better understand the performance of nuclear grade FeCrAl cladding in a BWR during dryout conditions caused by an Anticipated Operational Occurrence or Anticipated Transient Without SCRAM - both of which are Design Basis Accidents. Internally pressurized C26 M FeCrAl alloy cladding and Zircaloy-2 cladding were subjected to rapid 300°-650 °C thermal cycling in a steam environment; actual maximum temperatures were found to vary between materials but were always above 650 °C. In the range of 32–55 MPa hoop stress, Zircaloy-2 cladding burst within 1–16 cycles (about 100 s of dryout duration above 600 °C), while at 76 MPa hoop stress, C26 M cladding remained virtually undeformed after completing 54 cycles (over 1000 s of dryout duration above 600 °C). Higher temperature 300°-700 °C and 300°C–800 °C cycling experiments had to be performed to induce C26 M burst – failure occurred after 20 cycles in the former and during the first cycle in the latter. Zircaloy-2 and C26 M failure criteria were used to generate hoop stress specific dryout lifetimes. Overall, the simulated cyclic dryout experiments show that nuclear grade C26 M cladding has significantly enhanced survivability under dryout conditions relative to Zircaloy-2.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2020

Mechanical and chemical properties of PVD and cold spray Cr-coatings on Zircaloy-4

In this paper, accident-tolerant fuel (ATF) cladding materials aim to improve fuel reliability and safety during accident scenarios in water-cooled reactors. These ATF cladding should also perform comparable or better than the current zirconium alloy cladding under reactor normal operating conditions. Surface-modified Zircaloy-4 was produced by depositing a protective coating of chromium by two different coating techniques, Physical Vapor Deposition (PVD) and Cold Spray (CS). The coating thickness, structure, composition, and mechanical properties of the coated Zircaloy were assessed with advanced materials characterization techniques. Results showed a strengthening effect of the Cr-coating, along with ~83% higher hardness compared to that of the Zircaloy-4 substrate. Surface topography and surface chemistry of the Cr-coated Zircaloy-4 were assessed with contact profilometry, atomic force microscopy, contact angle goniometry, and X-ray photoelectron spectroscopy. Deposited Cr-coating significantly improved surface wettability compared to the substrate Zircaloy-4. The formation of surface oxides on the coatings by prolonged exposure to ambient air showed a further increase in the hydrophobic behavior. Surface parameters and surface chemistry after flow boiling critical heat flux tests, conducted at atmospheric pressure, evidenced a slight increase in surface roughness with notable changes in wettability associated with the formation of surface oxides.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Investigation of the irradiation effects in additively manufactured 316L steel resulting in decreased irradiation assisted stress corrosion cracking susceptibility

While additive manufacturing (AM) is an area of increasing interest to the nuclear industry, there are significant research and development needs prior to successful implementation of additively manufactured components into reactors. AM steel behaves differently than traditional wrought material, as has been observed in numerous mechanical testing studies. The nuclear industry must also understand the material response to irradiation. This work examines the irradiation damage and the irradiation assisted stress corrosion cracking behavior (IASCC) of both proton irradiated AM and wrought 316L steel. For IASCC testing, specimens were strained to 4% plastic strain in a simulated boiling water reactor environment (288°C, 0.2 µS/cm). Transmission and scanning electron microscopy, confocal microscopy, and X-ray computed tomography were used to examine coupons of the material as well as tensile bars used in the IASCC testing. This work found that the wrought 316L was more susceptible to IASCC than the AM steel, however, some IASCC was observed in the AM steel when tested with the tensile axis parallel to the build direction. Electron microscopy has shown significantly fewer radiation induced voids formed in the AM steel. While the pre-existing pore network in the AM steel may act as a sink to point defects, this is not expected to be the major factor in the reduced swelling observed in the AM steel. The lower density of radiation induced voids was expected to contribute to the IASCC resistance by decreasing the localization of deformation in the irradiated specimens, however, severity of localized deformation in AM steel, measured in dislocation channel spacing and height, was similar or more severe to that found in wrought. In conclusion, the presence of severe cracking in the wrought specimens did not allow for a direct comparison of localized deformation severities between the AM and wrought steel.

Additive manufacturing↗
DOE OSTI2021

Correlative STEM-APT characterization of radiation-induced segregation and precipitation of in-service BWR 304 stainless steel

In this study, radiation induced segregation and precipitation phenomena in an in-service boiling water reactor 304 stainless steel component were investigated using directly correlated 3D-atom probe tomography and scanning transmission electron microscopy. Significant quantitative differences in measured segregation at grain boundaries were found between the atom probe and energy dispersive spectroscopy measurements of the exact same locations. In particular, a much stronger Si segregation (~10 atomic% via atom probe versus ~4 atomic% via electron microscopy) and different Cr profile shapes were detected that are critical to models of radiation induced segregation and stress corrosion cracking behavior. These quantitative differences highlight the need for comparative microscopy and critical evaluation of limitations in each analytical method. Elemental segregation to dislocations and conjoined-clusters were also highlighted by atom probe; confirming and expanding upon what has been observed in test reactor neutron and accelerator-based ion irradiations.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Radiation Effects Related to Repaired BWR Core Shrouds

The material properties of the core shroud and supporting tie rod components are important factors for Boiling Water Reactor (BWR) life extension considerations. Given the variability of nickel and boron content found in 304 stainless steel shroud plates, and XM-19 and Inconel X-750 tie rod materials, this paper combines the latest spectral information in the vicinity of the core shroud to calculate hydrogen and helium gas production limits as well as atomic displacement damage spanning 80 full-power years (FPY) using the SPECTER code. Results indicate that, whereas boron has little effect on the atomic displacement damage, helium production from boron can be important and must be included in weldability assessments. Since the boron concentration is uncertain, helium generation is calculated assuming a composition range based on specifications and reported measurements. The results show that helium production caused by transmutations in the 304 SS shroud material are dominated by the concentration of boron and will have a significant impact on weldability after only a few years of service. For tie rods, the susceptibility to irradiation-assisted stress corrosion cracking (IASCC) has been assessed by determining helium production in Inconel X-750 IASCC specimens irradiated in the Advanced Test Reactor (ATR) reactor and correlating with the helium produced in a BWR. As a tie rod material in a high thermal neutron flux environment, Inconel X-750 is more likely to be IASCC sensitive during service in a BWR due to helium than the XM-19 stainless steel alloy because of a greater nickel content and boron concentration. Weldability of the core shroud plate material, IASCC of the tie rod materials, and the gamma photon contribution to radiation damage are discussed.

radiation damage in materials, BWR↗