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DOE OSTI2019

Multifunctional Liquid Marble Compound Lenses

Mosquito compound eyes are elaborate multifunctional hierarchical structures. The presence of ordered curved features spanning length scales of nanometers to millimeters provides the mosquito eye with a wide field of view, an infinite depth of field, as well as antifogging properties. Developing bio-inspired compound lenses is challenging because of the need to mimic all characteristic curvatures along with their functionalities. Herein, we show how the curvature inherent to nanoparticles, emulsion droplets, and liquid marbles can be employed to mimic the hierarchical structure and functionality of mosquito compound eyes. At the nanometers to micron length scale we employ nanoparticle-stabilized emulsion droplets of photocurable oil to form microlenses with nanoscale surface features. After polymerization, the microlenses form a monolayer on an oil droplet to create an optically clear, millimeter scale, liquid marble that functions as a compound lens. Here, we characterize the optical and surface properties of the compound lenses and find that they reproduce the functionality of the mosquito eye. Furthermore, we exploit the mobility and reconfigurability of liquid marbles to create arrays (centimeter scale) of compound lenses and other types of functional lenses such as the Janus lens that magnifies the image acquired by the compound lens. Simple and scalable methods to create compound lenses could aid in the development of miniaturized advanced vision systems.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Velocity Profiling of a Gas–Solid Fluidized Bed Using Electrical Capacitance Volume Tomography

In this study, a method of producing velocity profile maps from electrical capacitance volume tomography (ECVT) measurements by reconstructing displacement from measured changes in capacitance is developed and applied to fluidized bed systems. The mapping of the reconstruction leverages the gradient of the sensitivity distribution of the ECVT sensor to circumvent the need for image cross correlation techniques. Experimental data of both bubbling and slugging fluidized beds are collected in a cold flow model. Adaptation of the technique is discussed in detail, and velocity profiles are obtained for a range of gas flow rates. The produced velocity maps are compared against the established methods of cross correlation and against empirical correlations from the literature and are found to agree well in tracking slug and bubble velocity. The exception is when the tracked object is large relative to the ECVT sensor dimensions, a scenario that can be avoided through proper sensor design. The quantities of average velocity, momentum, and solid and gas volume fraction are derived from the image and velocity profiles. The results demonstrate and extend the power of ECVT as a measurement tool for the study and monitoring of gas–solid fluidized beds by providing a computationally cheaper alternative to 3-D cross correlation for deriving velocity profiles.

47 OTHER INSTRUMENTATION↗

DOE OSTI2018

SECARB 3D VSP Data

Vertical Seismic Profile data collected in 2009 and 2010 as part of SECARB Phase III Early Test at Cranfield oilfield in Mississippi to determine CO2 induced change from seismic response. Data divided into 3D VSP and Offset VSP folders. Associated Publications: Daley, T. M., Hendrickson, J., & Queen, J. H. (2014). Monitoring CO2 Storage at Cranfield, Mississippi with Time-Lapse Offset VSP – Using Integration and Modeling to Reduce Uncertainty. Energy Procedia, 63, 4240-4248. doi:10.1016/j.egypro.2014.11.459

3D VSP↗

DOE OSTI2017

BWR Full Fuel Assembly Testing and Validation

This report describes the Consortium for Advanced Simulation of Light Water Reactors (CASL) work conducted for completion of the Thermal Hydraulics Methods (THM) Level 3 milestone THM.CLS.P15.10: BWR Full Fuel Assembly Testing and Validation. The extension of existing boiling closure designed for Pressurized Water Reactors (PWRs) to the high void fraction condition of Boiling Water Reactors (BWRs) is one of the challenges for Multiphase Computational Fluid Dynamics (M-CFD) applications. In the efforts aimed at developing the advanced boiling closure for BWRs, the baseline closure model, so-called ‘Zero’ closure, has been developed based on the GEN-I closure for PWRs which was used as a starting point. Since this simplest closure model is robust but does not contain any explicit description of the complex high void fraction mechanisms, the applicability of M-CFD needs to be evaluated before developing advanced closures for BWRs. To support this need, the high fidelity M-CFD simulation with Zero closure has been conducted for the BWR full fuel assembly. The capabilities of M-CFD with Zero closure were evaluated against the international OECD/NRC BFBT benchmark data. The scalability of the M-CFD application to the nuclear fuel assembly was demonstrated with the INL High Performance Computing (HPC) system. This report presents the recent view of the best practices on M-CFD for BWRs to provide a useful reference to identify and overcome common challenges in the M-CFD applications.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2018

MFIX-DEM Phi: Performance and Capability Improvements Towards Industrial Grade Open-source DEM Framework with Integrated Uncertainty Quantification

Two major challenges hinder the effective use and adoption of multiphase computational fluid dynamics tools by the industry. The first is the need for significant computational resources, which is inversely proportional to the accuracy of solutions due to computational intensity of the algorithms. The second barrier is assessing the prediction credibility and confidence in the simulation results. In this project, a multi-tiered approach has been proposed under four broad activities to overcome these challenges while addressing all of the objectives outlined in FOA-0001238 through Phases 1 and 2 of the project. The present report consists of the results for only Phase 1, which was the funded performance period. From the start the project, all of the objectives outlined in FOA were addressed through four major activity tasks in an integrated and balanced fashion to improve adoption of MFIX suite of solvers for industrial use. The first task aimed to improve the performance of MFIX-DEM specifically targeting to acquire the peak performance on Intel Xeon and Xeon Phi based systems, which are expected to be one of the primary high-performance computing platforms both affordable and available for the industrial users in the next two to five years. However, due to a number of changes in course of the project, the scope of the performance improvements related task was significantly reduced to avoid duplicate work. Hence, more emphasis was placed on the other three tasks as discussed below. The second task aimed at physical modeling enhancements through implementation of polydispersity capability and validation of heat transfer models in MFIX. An extended verification and validation (V&V) study was performed for the new polydispersity feature implemented in MFIX-DEM both for granular and coupled gas-solid flows. The features of the polydispersity capability and results for an industrially relevant problem were disseminated through journal papers (one published and one under review at the time of writing of the final technical report). As part of the validation efforts, another industrially relevant problem of interest based on rotary drums was studied for several modes of heat transfer and results were presented in conferences. Third task was aimed towards an important and unique contribution of the project, which was to develop a unified uncertainty quantification framework by integrating MFIX-DEM with a graphical user interface (GUI) driven uncertainty quantification (UQ) engine, i.e., MFIX-GUI and PSUADE. The goal was to enable a user with only modest knowledge of statistics to effectively utilize the UQ framework offered with MFIX-DEM Phi to perform UQ analysis routinely. For Phase 1, a proof-of-concept demonstration of the proposed framework was completed and shared. Direct industry involvement was one of the key virtues of this project, which was performed through forth task. For this purpose, even at the proposal stage, the project team received strong interest in the proposed capabilities from two major corporations, which were further expanded throughout Phase 1 and a new collaboration with another major corporation from chemical industry was also initiated. The level of interest received and continued collaboration for the project during Phase 1 clearly shows the relevance and potential impact of the project for the industrial users.

42 ENGINEERING↗

DOE OSTI2018

Validation and optimization of batch and continuous particle separation processes

Recent advances in simulation capabilities coupled with advanced manufacturing can be leveraged to create highly efficient compact reactors with low emissions, low cost, high reliability, and high flexibility for energy conversion. This type of reactor is especially important for conversion of bio-mass, a storable, renewable and fast-growing energy source, considering the distributed nature of raw material and cost of biomass collection and transportation. To achieve this goal, it is critical to developing new process technologies that are significantly more efficient than traditional processes for which the added manufacture provides a fast way of realization and evaluation. Based upon the flagship MFiX multiphase computational fluid dynamic software suite, NETL has developed an Optimization Toolset to facilitate the CFD simulation based reactor design and optimization, and process intensification. This technical report presents the recent development and application of the Optimization Toolset and the framework for process optimization of particle separation in batch and continuous processes. In these processes, a fluidized bed reactor under proper operating condition was used to separate particles of different physical properties. MFiX-DEM simulations were conducted for a batch system to simulate the process covering a wide range of superficial gas velocities from which the optimal operational parameter can be determined through analyzing the system response. After successful demonstration of the framework, a continuous system for particle separation was designed based on CFD simulations. Similar optimization exercises were conducted for the continuous particle separation considering multiple operating parameters. The design was then fabricated in the laboratory through 3D printing for testing. The particle separation performance was carefully measured through high-speed video for particle tracking. Quantitative comparison between numerical results and experimental measurements were conducted for confirmation and validation.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2020

Status Update: Deposition Modeling For SNF Canister CISCC

This report fulfills the M3 milestones M3SF-21PN010207025 & M3SF-20PN0102070412. During fiscal year (FY) 2020, Pacific Northwest National Laboratory (PNNL) worked to further develop the FY 2019 deposition and particle tracking models. This status report outlines these efforts and presents the progress made so far. Model development work is ongoing and is planned to continue in FY 2021. The FY 2020 model development included work on: Wind Effects. Model development and sensitivity studies, investigated how wind direction and speed affect deposition; Brownian Motion. Implementing Brownian Motion into existing models; Particle Size Variability. Depending on the particle composition, the diameter of the particle may vary with changes in relative humidity. Models were developed to analyze this; Multiphase and Fluid Film Modeling. Investigating canister surface wetting and drying, and how this effects overall deposition. Models were developed to analyze this; Difusophoresis. Performing initial work to implement diffusiophoresis into the existing models; Turbophoresis. Performing initial work to implement turbophoresis into the existing models. Much of this work will continue into FY21. The authors present initial results and discus current and future work.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2021

MFIX DEM Enhancement for Industry-Relevant Flows (Final Report)

The overall goal of this two-phase project is to implement performance improvements of the Multiphase Flow with Interphase Exchanges (MFIX) Discrete Element Model (DEM) code that enable a transformative shift for industrial use. Prior to this effort, the largest simulations performed using MFIX are O(10 7 ) particles. This falls short of the O(10 9 ) particle simulations that must be completed on a timescale of days or weeks (vs. months or years) to enable simulations with physically-relevant domain sizes to be incorporated into industrial design cycles within five years. This was accomplished by tailoring best-in-class practices to bear on the unique challenges posed by the MFIX-DEM algorithm and code base. Scientific simulations (e.g., in cosmology, turbulent combustion) routinely use massively parallel computing to update far more particles in short wall clock times. Results from Phase 1 (1.5 years in duration) indicated significant gains in speed were possible for a wide range of benchmark cases. Moreover, a survey sent to >35 companies indicates that the timing is ideal for such an enhanced tool, with >80% of the respondents indicating that DEM is already value-added or will be within the next 5 years, and >70% of the respondents indicating that improved speed is the top computational priority. In Phase 2 (3.5 years in duration), the two major barriers that hinder industry from effectively using multiphase Computational Fluid Dynamics (CFD) to cut costs and improve performance, namely computational overhead and confidence in predictions, continued to be addressed. Regarding the former, the results from Phase 1 to guide the effort, with enhancements focused on an improved time-stepping algorithm and particle sorting. Four target problems of 1 billion particles each and increasing complexity were identified: homogeneous cooling, tumbler with continuous particle size distribution, discharge from a rectangular hopper and a cylindrical riser. Each of these were successfully simulated for relevant time scales (on order of seconds) using less than 24 hours of wall clock time. These represent the first 1-billion particle DEM simulations performed with MFIX, namely using the MFIX-Exa code. This code is currently under development at NETL in collaboration with Lawrence Berkeley National Laboratory. Regarding the second barrier on predictive uncertainty, experiments from Phase 1 (interacting nozzles - hydrodynamics only) and Phase 2 (very small-scale segregation experiments) were used to demonstrate the ability of two simplified approaches to uncertainty quantification (UQ). By limiting the number of particles, UQ based on the simplified treatment was compared to standard UQ, which was shown to have much higher computational demands. Experiments were also performed on a pilot-scale stripper unit to provide validation data for future CFD-DEM simulations and UQ.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2018

Gen-0 BWR Modeling Application and Validation (L3 Milestone THM.P18.01)

This milestone report describes the Consortium for Advanced Simulation of Light Water Reactors (CASL) work conducted for completion of the thermal hydraulics Methods (THM) Level 3 milestone L3:THM.P18.01 Gen-0 BWR Modeling Application and Validation. The extension of existing boiling closure designed for Pressurized Water Reactors (PWRs) to the high void fraction condition of Boiling Water Reactors (BWRs) is one of the challenges for Multiphase Computational Fluid Dynamics (M-CFD) applications. In the efforts aimed at developing the advanced boiling closure for BWRs, the baseline closure model, so-called ‘Zero’ closure, has been developed by leveraging the experience gained through the Numerical Nuclear Reactor project. This baseline closure model is physics-based, simplest and robust, but it does not contain any explicit descriptions of the complex high void fraction mechanisms. This is a continuation of the CASL thermal-hydraulic study to develop and assess the CFD-BWR models. In FY-17, the applicability has been evaluated against the international OECD/NRC BFBT benchmark data. In the present work, we assessed the capability of CFD-BWR model for void drift phenomena in the modern BWR fuel designs which make use of both full-length and part-length rods.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2023

Niowave Neutron Source Converter: Lead-Bismuth-Eutectic (LBE) Windowless Target Design and Evaluation

Los Alamos National Laboratory (LANL) is working with Niowave on the design and evaluation of their lead-bismuth-eutectic (LBE) windowless target (i.e., neutron source converter). Niowave plans to use 200 kW electron beam at 40 MeV beam energy to produce neutrons by photonuclear reaction with LBE. Then, the neutrons undergo fission at the surrounding uranium target assembly (UTA) to produce Molybdenum 99 (Mo-99) as a fission product, which eventually decays to Technetium-99 (Tc-99m). Tc-99m is one of important radioisotopes that is used for medical diagnostics. LANL conducted 3D multiphysics analysis for the Niowave neutron converter design and provided design assessment in thermohydraulic aspects. LANL conducted radiation transport calculations using Monte-Carlo N-Particle (MCNP) code with unstructured meshing scheme. The 3D volumetric heating profiles in the LBE and Stainless-Steel (SS) housing were imported into multiphase computational fluid dynamics (CFD) to obtain 3D temperature profiles of LBE and SS through conjugate heat transfer (CHT) analysis. The key findings are: LBE film thickness at the center of the beam is approximately 1.6 cm with a maximum LBE velocity of approximately 1.8 m/s, which is below a 2 m/s limit to avoid erosion issues on supporting structures; Heat deposition in the LBE peaks at ~1 cm depth from the LBE free-surface because of the forward interactions of electron, photon, and neutron with LBE; LBE maximum temperature is ~360 °C, which is below LBE evaporation initiative temperature, ~450 °C; LBE-SS interface temperature is ~350 °C, which is below the safety thermal limit to prevent severe corrosion on SS. The results indicate that Niowave’s neutron converter design satisfies both hydraulic and thermal criteria for safe operation. By virtue of such computational analysis, Niowave can move toward establishing an experimental setup to experimentally test their LBE neutron converter. The following sections describe the detailed work done by LANL.

43 PARTICLE ACCELERATORS↗

DOE OSTI2023

MFiX: Fractional-Step Method Implementation

A comprehensive, multiphase computational fluid dynamics (CFD) simulation solves several coupled transport equations including continuity, momentum, species, and energy. Chemical reactions further couple these equations through heats of reaction and rates of formation of products and rates of destruction of reactants. A fractional-step method separates changes attributed to chemical reactions from transport phenomena like convection and diffusion. When the governing equations are split into the transport and reacting components, efficient and independent methodologies can be exploited to solve the different systems. Specifically, discretization of field variable transport equations results in large, sparse matrices which are loosely coupled. These systems are solved in succession using iterative techniques that take advantage of the matrix structure. In contrast, chemical reactions tightly couple field variables locally within the domain (e.g., within a single computational cell) resulting in low dimensional but dense, nonlinear systems that are better solved using direct integration techniques.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

A Comparison of GPU-Accelerated Multiphase CFD Solvers on the Polaris Supercomputer: Part 1

This report is in support of the Innovative and Novel Computational Impact on Theory and Experiment (INCITE) program sponsored by the U.S. Department of Energy (USDOE). With INCITE-level resources, one project, titled BubblyFlow, was granted computational resources for the 2025 calendar year on the Polaris supercomputer at the Argonne Leadership Computing Facility (ALCF). The project aims to conduct simulations to understand the fundamental characteristics of turbulent bubbly flow phenomena in nature. Staff at the ALCF and Argonne’s Computational Science division, along with collaborators at the City College of New York and University of Illinois at Chicago, helped a summer student to assess the accuracy and performance of two high performance computing (HPC) codes. Both codes, ImExLBM and FluTAS, are fundamentally different in their mathematical and numerical modeling. However, both may be used to solve the same physical problem. The collaboration sought to better understand the differences between both codes in terms of accuracy and efficiency. This would ultimately help the BubblyFlow project better utilize resources and establish a knowledge-base of code capabilities in future simulation campaigns. We compare ImExLBM and FluTAS, two high-performance multiphase computational fluid dynamics (CFD) solvers, in terms of physical fidelity, time-to-solution, and parallel efficiency. We validate ImExLBM (Implicit-Explicit Lattice Boltzmann Method) against a canonical benchmark and assess it’s performance relative to FluTAS (Fluid Transport Accelerated Solver), a well-established open-source CFD code.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2026

Seawater Acidification and Bubble Plume Dispersion from Accidental Subsea CO 2 Pipeline Rupture: A Multiphase CFD Study

If a CO 2 reservoir or transmission pipeline were to leak, both the surrounding ecology and maritime traffic safety could be put at risk. To better understand and prepare for this risk, multiphase Computational Fluid Dynamics (CFD) models were built in ANSYS Fluent to capture the behavior of a leak once it enters the water. A 3D Eulerian–Eulerian model was used for validation, while a simplified 2D model was applied to simulate conditions at a 50-m depth. The models integrate bubble dynamics, gas holdup, CO 2 dissolution, dissolved species transport, and seawater acidification into a unified CFD framework. Mass transfer was calculated using the Hughmark correlation, and local seawater temperature and salinity were factored in to determine dissociation behavior and the relevant Henry’s Law constant. To confirm the 3D model’s accuracy, results were checked against two experimental datasets: the QICS field study and the Hauser Tank experiments. The team also modeled a hypothetical release scenario at the High Island 10L site and compared the results with earlier published work. The results show that at a depth of 50 m, the surrounding water column can completely absorb a CO 2 release at a rate of 35 kg/s, since the gas dissolves into the seawater as it rises toward the surface. Beyond confirming this mitigation capacity, the simulations shed light on how a leak would actually unfold in the environment, including the shape and movement of the rising bubble plume, how much CO 2 dissolves along the way, and the resulting shifts in seawater pH and pCO 2 . Together, this provides a practical framework for assessing how CO 2 leaks could affect marine environments in the Gulf of Mexico.

54 ENVIRONMENTAL SCIENCES↗

NASA NTRS1992

Multi-phase simulations of coaxial injector combustion

A multiphase computational fluid dynamics code (ARICC-3D) is presented and results of two simulations are discussed. The numerical framework of the CFD code is reviewed as well as some of the two-phase physical submodels. The simulations performed include a single coaxial element injector and a multielement injector using LOX/Hydrogen reactants. The single element injector simulation verified the interaction among the code's submodels. The multielement injector simulation transient results include the chamber response to a transverse pressure wave with and without a chamber baffle. The results of these simulations demonstrate the current capabilities and their limitations to model complex two-phase combustion phenomena. Possible ways to exceed these limitations are suggested.

Liang, P. Y.↗

NASA NTRS2017

Pressure-Fed LOX/LCH4 Reaction Control System for Spacecraft: Transient Modeling and Thermal Vacuum Hotfire Test Results

An integrated cryogenic liquid oxygen, liquid methane (LOX/LCH4) reaction control system (RCS) was tested at NASA Glenn Research Center's Plum Brook Station in the Spacecraft Propulsion Research Facility (B-2) under vacuum and thermal vacuum conditions. The RCS is a subsystem of the Integrated Cryogenic Propulsion Test Article (ICPTA), a pressure-fed LOX/LCH4 propulsion system composed of a single 2,800 lbf main engine, two 28 lbf RCS engines, and two 7 lbf RCS engines. Propellants are stored in four 48 inch diameter 5083 aluminum tanks that feed both the main engine and RCS engines in parallel. Helium stored cryogenically in a composite overwrapped pressure vessel (COPV) flows through a heat exchanger on the main engine before being used to pressurize the propellant tanks to a design operating pressure of 325 psi. The ICPTA is capable of simultaneous main engine and RCS operation. The RCS engines utilize a coil-on-plug (COP) ignition system designed for operation in a vacuum environment, eliminating corona discharge issues associated with a high voltage lead. There are two RCS pods on the ICPTA, with two engines on each pod. One of these two engines is a heritage flight engine from Project Morpheus. Its sea level nozzle was removed and replaced by an 85:1 nozzle machined using Inconel 718, resulting in a maximum thrust of 28 lbf under altitude conditions. The other engine is a scaled down version of the 28 lbf engine, designed to match the core and overall mixture ratios as well as other injector characteristics. This engine can produce a maximum thrust of 7 lbf with an 85:1 nozzle that was additively manufactured using Inconel 718. Both engines are film-cooled and capable of limited duration gas-gas and gas-liquid operation, as well as steady-state liquid-liquid operation. Each pod contains one of each version, such that two engines of the same thrust level can be fired as a couple on opposite pods. The RCS feed system is composed of symmetrical 3/8 inch lines that tap off of the main propellant manifold to send LOX and LCH4 outboard to the RCS pods. A Thermodynamic Vent System (TVS) is used to condition propellants at each pod by venting through an orifice and then routing the cold expansion products back through tubing that is welded along a large portion of the main RCS feed lines. Prior to final installation on the ICPTA, the RCS engines were tested in a small vacuum chamber at the Johnson Space Center (JSC) Energy Systems Test Area (ESTA) to verify functionality of the new COP ignition system and check out operation of the vacuum nozzles. After engine-level testing, the RCS engines were installed on the vehicle and a series of integrated hot-fire tests were performed at JSC consisting of various pulsing and steady-state firings as well as integrated main engine/RCS operation. The ICPTA was then integrated into the Plum Brook B-2 facility for vacuum and thermal/vacuum testing. Testing in the B-2 facility was composed of multiple thermal and pressure environments. The first set of tests were performed under ambient temperature and altitude pressure conditions. These tests consisted of a range of minimum impulse bit (MIB) pulsing sequences with low duty cycle, analogous to a coast phase in which the RCS is primarily used for station keeping. The primary goal of this sequence is to understand how propellant conditions were effected without an active TVS. In this scenario, consistent gas-gas operation is desirable since it results in a smaller MIB and more efficient propellant consumption. Multiple skin thermocouples are mounted on the feedlines, in addition to a submerged thermocouple on each commodity, in order to gather thermal data on the system. Higher duty cycle pulsing tests were then performed, analogous to an ascent or landing mission phase. The primary goal of this sequence was to examine how well the engines self-conditioned without active TVS when starting from a quiescent state. The TVS was then activated during some tests to demonstrate the capability to quickly condition the engines for higher pulsing demand scenarios. A thermocouple at the TVS outlet allows for the calculation of energy absorbed by the vented propellant. Lastly, tests with longer pulses and multiple engines firing either in sequence or simultaneously were run in order to gather transient system response data on waterhammer. Six total high-speed pressure transducers are installed on the RCS system, one sensor at the end of each propellant manifold line on the pods, and one at the tap-off location for each commodity. This will allow for the accurate characterization of waterhammer in the system under various propellant conditions and firing sequences. Other instrumentation for this test series includes nozzle throat thermocouples, chamber pressure measurement, heat soakback measurement, and tank wall plume impingement temperature measurement. The next set of tests were performed to demonstrate simultaneous main engine and RCS operation. Data from this test will be used to examine if there is any change to nominal operation of the RCS as a result of feed system interaction or other phenomenon. Some of these tests began under high vacuum conditions (target ambient pressure less than 1x10(exp -3) torr) and others began at altitude conditions. The last set of tests were performed with the B-2 cold wall active. Under these tests, many of the same low duty cycle MIB tests were repeated in order to characterize how propellant conditions changed with the lower heat leak. In this scenario the RCS manifold experiences much less heat leak, resulting in a change to how well the engines self-condition. As a result, an increase in maximum waterhammer pressures and a change in natural frequency of the system was expected due to higher density propellants. The lower heat leak should also result in a change to the MIB pulse profile, and data will be examined to understand how MIB repeatability is affected in the different operating environments. Parallel to the test efforts, a set of transient model development efforts were made to predict RCS performance. The primary effort was aimed at producing a SINDA/FLUINT model to predict propellant conditioning up to the engine inlet as a function of different environmental and operating parameters, with the goal of predicting chamber pressure, TVS performance, and propellant consumption over time. Preliminary results for this effort will be presented in comparison with test data. Additional modeling efforts were made using SINDA/FLUINT to predict waterhammer in the system since the software is capable of handling multiphase transient fluid dynamics. These results will be compared with the high-speed pressure transducer test data for validation purposes.

Atwell, Matthew J.↗

DOE OSTI2019

250 kWth Pilot Testing in Support of a 10 MWe Coal-Direct Chemical Looping Demonstration Feasibility Study

The Coal-Direct Chemical Looping (CDCL) process is emerging as a promising technology capable of high efficiency for producing electricity with low cost for carbon capture. In the CDCL process, coal is fully combusted to form carbon dioxide (CO2) and water via reaction with Fe2O3-based oxygen-carrier particles in a moving-bed reducer reactor. During reaction with coal, the Fe2O3 is reduced to form a mixture of Fe and FeO. The reduced particles are then transported to the combustor reactor where they are re-oxidized with air. The oxidation of the Fe and FeO mixture generates heat that can be used to produce steam for power generation. Once the particles are fully regenerated, they are pneumatically recycled to the reducer reactor where another reduction-oxidation (Redox) cycle begins. The Babcock & Wilcox Company (B&W) and The Ohio State University (OSU) have been developing the CDCL technology based on iron-based metal oxide particles circulating in a moving-bed reducer coupled with an entrained-flow combustor. As part of a Phase I effort of a DOE-sponsored project, B&W identified scale-up technology gaps for the coal-direct chemical looping reactor process, most of which fall under the moving-bed reactor design and operation. However, after the Phase I research, B&W concluded that the CDCL technology has the potential of generating electricity while meeting the DOE goals of greater than 90% CO2 capture and less than 35% increase in levelized cost of electricity (LCOE). B&W then moved to a Phase II project to design, build and demonstrate the CDCL technology at a 250 kWth capacity. B&W finished the construction and commissioning of the pilot test facility in 2017. The approach used to design a 250 kWth pilot-scale CDCL facility to investigate the technology gaps is presented. Important lessons from the commissioning activities that would transfer to commercial plant start-up are also shared. The findings from the test program are being incorporated into a Pre-FEED study for a 10 MWe large pilot demonstration. Under a separately-funded heat integration project, B&W and OSU are developing a multiphase computational fluid dynamic model (MFIX) of the combustor to quantify heat transfer to embedded steam generation surface, utilizing pinch analysis (ASPEN Energy Analyzer) to identify potential improvements of the heat integration scheme, and developing an integrated dynamic model (ProTRAX) of the steam turbine coupled with the chemical looping process to identify potential start-up and transient operation issues. Under an advanced control system for optimizing operation, B&W is supporting OSU to install a rules-based optimizer (B&W’s FocalPoint) on their 25 kWt bench-scale facility on the OSU West Campus. Finally, B&W and OSU were recently selected to perform a Phase I Feasibility study to evaluate installation of the 10 MWe pilot at the Dover Power & Light Municipal Power Plant in Dover, Ohio. The feasibility study includes compiling an Environmental Information Volume and generating a cost estimate for the design, construction and commissioning of the plant as well as lining up commitments from potential project participants and funding contributors. Updates on each project will be presented. The status of the technology development will be discussed. We focus on the progress made to date towards closing the technology gaps under each project.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2018

Update on Design of 10 MWe Iron-Based Coal Direct Chemical Looping Demonstration Plant

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2022

Interface Capturing Simulations on Pool Boiling Performance With Multiple Nucleation Sites

High-fidelity pool boiling simulations can provide a numerical database for improving mechanistic boiling models by allowing for specific evaluation of interactions among bubbles. Previously published pool boiling simulations investigated two nucleation sites in which bubble growth at one site suppressed nucleation at the other site. Based on previous study results, more complicated interface-capturing simulations on pool boiling were conducted using PHASTA code with locally refined unstructured mesh.First, different boundary conditions (BCs) were assessed to support robustness and reproducibility of the boiling model. Then, a scale study was conducted at a larger domain with nine nucleation sites, four of which were activated. Involving more nucleation sites increased the complexity of bubble interactions from surrounding sites. Finally, bubble departure behavior influenced by wall heat flux was investigated. When heat flux was increased, the order of bubble departure changed, but diagonal bubbles always departed after one another. The departure time interval between the first and second bubble reduced as heat flux increased. The corresponding frequency was almost linearly proportional to the heat flux. In addition, bubble departure behavior was found to be greatly influenced by the nucleation site pattern. Multiple nucleation sites resulted in superimposed inhibitive effects from surrounding sites to each bubble, which extensively delayed the departure.The work presented here provides new insight on the fundamental understanding of boiling phenomena, contributes to the development of a 3D multiphase computational fluid dynamics (M-CFD) model, and provides a more comprehensive database for data-driven pool boiling studies.

Fan, Joy↗