Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Steam generator”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2018

Chinese Ink: A Powerful Photothermal Material for Solar Steam Generation

Solar steam generation offers signifcant promise in alleviating fresh water crises, particularly in regions with accessible seawater and abundant insolation. Affordable, efficient, and environmentally friendly photothermal materials are needed to fabricate sunlight-driven evaporation devices. In this work, Chinese ink, a carbon-based paint used in traditional painting and calligraphy, is readily coated on diverse substrates and stabilized by atomic layer deposition (ALD) for solar steam generation. The ALD/Chinese ink coating exhibits strong and broad light absorption from the NIR to UV regions. Both ALD/Chinese-ink-coated membranes and wood display excellent photothermal properties and superior evaporation performance under simulated sunlight. This study demonstrates the potential of ALD/Chinese ink coating to achieve higher evaporation rate and efficiency by utilizing substrates with rough, structured surfaces and low thermal conductivity.

36 MATERIALS SCIENCE↗
DOE OSTI2021

ADVANCED THERMAL-HYDRAULIC MODEL OF HEAT RECOVERY STEAM GENERATORS

Steam-side oxidation at elevated temperatures in heat recovery steam generators (HRSGs) can lead to overheating of local tubes, potential oxide scale exfoliation, and damage to critical equipment. Predicting the oxide growth distribution requires detailed knowledge of the distribution of tube metal temperatures. To address these challenges, a computational fluid dynamics (CFD) model of a high-pressure superheater (HPSH) was developed within the Siemens’ STAR-CCM+ CFD commercial software. The HPSH section of the steam generator was selected for modeling because of its high oxidation rates.The model development included several steps. In the first step, an oxidation model based on a parabolic oxidation relationship was implemented. The oxidation growth predicted by the model was then verified for a full-load boiler operation case. In the second step, a three-dimensional CFD model was developed to account for the thermal and flow physics involved in HRSGs. The CFD model was then verified and validated on a simplified geometry that contained six row-tubes which mimicked the tube arrangements of an HPSH section. Numerical results compared well with published experimental results. In the third step, the oxidation model was coupled to the HRSG’s CFD model, and a comparison study was performed for two cases: (a) regular finless tubes and (b) finned tubes. Preliminary results showed that the oxide thickness predicted by the case with tube fins was higher compared to that of the finless tube case, thus demonstrating the need to model the effects of the tube fins on oxide thickness.

Panicker, Nithin↗
DOE OSTI2017

Flow-induced vibration analysis of a helical coil steam generator experiment using large eddy simulation

This paper describes a numerical study of flow-induced vibration in a helical coil steam generator experiment conducted at Argonne National Laboratory in the 1980s. In the experiment, a half-scale sector model of a steam generator helical coil tube bank was subjected to still and flowing air and water, and the vibrational characteristics were recorded. The research detailed in this document utilizes the multi-physics simulation toolkit SHARP developed at Argonne National Laboratory, in cooperation with Lawrence Livermore National Laboratory, to simulate the experiment. SHARP uses the spectral element code Nek5000 for fluid dynamics analysis and the finite element code DIABLO for structural analysis. The flow around the coil tubes is modeled in Nek5000 by using a large eddy simulation turbulence model. Transient pressure data on the tube surfaces is sampled and transferred to DIABLO for the structural simulation. The structural response is simulated in DIABLO via an implicit time-marching algorithm and a combination of continuum elements and structural shells. Tube vibration data (acceleration and frequency) are sampled and compared with the experimental data. Currently, only one-way coupling is used, which means that pressure loads from the fluid simulation are transferred to the structural simulation but the resulting structural displacements are not fed back to the fluid simulation

CFD↗
DOE OSTI2019

High-Fidelity Simulation of Flow-Induced Vibrations in Helical Steam Generators for Small Modular Reactors

Flow-induced vibration (FIV) is a widespread problem in energy systems as they rely on fluid movement for energy conversion. Vibrating structures may be damaged as fatigue or wear occur. Given the importance of reliable components in the nuclear industry, FIV has long been a major concern in the safety and operation of nuclear reactors. In particular, nuclear fuel rods and steam generators have been known to suffer from FIV and related failures. In this paper we discuss the use of the computational fluid dynamics code Nek5000 coupled to the structural code Diablo to simulate the flow in helical coil heat exchangers and associated FIV. In particular, one-way coupled calculations are performed, where pressure and tractions data are loaded into the structural model. The main focus of this paper is on validation of this capability. Fluid-only Nek5000 large eddy simulations are first compared against dedicated high-resolution experiments. Then, one-way coupled calculations are performed with Nek5000 and Diablo for two data sets that provide FIV data for validation. These calculations were aimed at simulating available legacy FIV experiments in helical steam generators in the turbulent buffeting regime. In this regime one-way coupling is judged sufficient since the pressure loads do not cause substantial displacements. It is also the most common source of vibration in helical steam generators at the low flows expected in integral pressurized water reactors. We discuss validation of two-way coupled experiments and benchmarks toward the simulation of fluid elastic instability. We briefly discuss the application of these methods to grid-to-rod fretting.

Flow-Induced Vibration↗
DOE OSTI2018

Contactless steam generation and superheating under one sun illumination

Steam generation using solar energy provides the basis for many sustainable desalination, sanitization, and process heating technologies. Recently, interest has arisen for low-cost floating structures that absorb solar radiation and transfer energy to water via thermal conduction, driving evaporation. However, contact between water and the structure leads to fouling and pins the vapour temperature near the boiling point. Here we demonstrate solar-driven evaporation using a structure not in contact with water. The structure absorbs solar radiation and re-radiates infrared photons, which are directly absorbed by the water within a sub-100 μm penetration depth. Due to the physical separation from the water, fouling is entirely avoided. Due to the thermal separation, the structure is no longer pinned at the boiling point, and is used to superheat the generated steam. We generate steam with temperatures up to 133 °C, demonstrating superheated steam in a non-pressurized system under one sun illumination.

14 SOLAR ENERGY↗
DOE OSTI2022

Steam generator for fuel cell applications

A steam vaporizer assembly includes an internal steam generator having a vessel configured to hold water, a vaporizer unit having a heating element configured to heat the water to generate saturated steam; and a controller configured to: cause the heating element to heat the water to a stand-by temperature; and while maintaining a water level of the water in the vessel between two control points: maintain the water in the vessel at the stand-by temperature until steam generation is required, and when steam generation is required, heating the water in the vessel from the stand-by temperature to a temperature at or above a vaporization temperature of the water using a heating element, to generate the steam.

Dobek, Frank↗
DOE OSTI2026

Evaluating alternative steam generation pathways in the food industry

Steam generation in the food sector requires substantial energy and cost expenditures, requiring nearly half of its energy intake. Here, we used life cycle assessment and life cycle cost assessment to investigate the cost and energy impacts of steam generating alternatives: NG, biomass and hydrogen boilers and grid-supplied and self-generated electric steam generation systems (electric boilers, renewable thermal energy storage and industrial heat pumps). The analysis starts with a set of average U.S. conditions, where biomass boilers are the most cost-competitive alternative to NG. In a series of scenarios beyond average conditions, the analysis shows energy procurement costs dominate the total life cycle cost for all technologies and, unfortunately, are highly variable geographically and temporally, significantly affecting the viability of the alternatives. Results show that site-energy consumption ranges from 0.3 MMBtu/klb for industrial heat pumps to 1.6 MMBtu/klb for biomass boilers, with heat pumps achieving up to 78% lower energy use compared to natural gas systems. For the steam costs, the results show a range between $\$$8 and $\$$50/klb for NG, with biomass following closely ($\$$11 – $\$$44/klb) and grey hydrogen and IHP next ($\$$13 – $\$$33/klb and $\$$6 - $\$$78/klb), with cost reductions if IHP's cooling is utilized. Factors like operating hours, the need for cooling, and the ability to negotiate utility rates complicate the decision, making site-specific analyses critical. Therefore, we present a decision-making matrix to help manufacturers identify which steam generating technology is the best business decision for their situation. Overall, these results highlight the importance of steam generation for the facility's organizational goals, as well as the criticality of conducting individual site analyses.

Biomass boilers↗
DOE OSTI2020

Steam generator with inclined tube sheet

A steam generation system may include a plurality of heat transfer tubes configured to circulate a secondary coolant of the steam generation system. The steam generation system may be thermally coupled to a reactor vessel, and the reactor vessel may be configured to house a primary coolant. Heat generated from within the reactor vessel may be transferred from the primary coolant to the secondary coolant. The steam generation system may further include an inclined tube sheet fluidly coupled to the plurality of heat transfer tubes. The inclined tube sheet may be attached to a wall of the reactor vessel in a non-horizontal orientation.

42 ENGINEERING↗
DOE OSTI2025

Steam Generators: Thermal Hydraulic Measurements and Instrumentation

Steam generators are integral components of both conventional and advanced reactors utilizing steam power cycles, as they influence the power conversion performance. Steam generator designs are highly influenced by the type of reactor coolant used, which mainly governs the different control, monitoring, and safety system actuation requirements. Therefore, the present work reviews the thermal hydraulics instrumentation within steam generators designed for pressurized water reactors (PWRs), high-temperature gas-cooled reactors (HTGRs), sodium fast reactors (SFRs), and molten salt cooled reactors (MSRs). Emphasis is given to measurement techniques that are either unique or particularly important to specific reactor types. Lastly, a discussion is provided on the instrumentation and measured parameters. The work identifies standard parameters of interest and is expected to aid the development of test beds and novel measurements techniques.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗
DOE OSTI2020

Integrated Evaporator for Efficient Solar-Driven Interfacial Steam Generation

Solar-driven interfacial steam generation is a promising technique for clean water production as it can minimize thermal loss by localizing solar-to-heat conversion at the air/liquid interface. Here we report an integrated solar-evaporator by partially growing two-dimensional polypyrrole microsheets within a melamine foam through chemical vapor polymerization. These microsheets can induce multiple light reflections within the foam, enable omnidirectional light absorption, provide abundant surfaces to promote heat transfer, and achieve spatially-defined hydrophobicity to facilitate vapor escape. Meanwhile, the inherent hydrophilicity of the bottom part of the foam promotes spontaneous upward water transport and suppresses heat loss. The composite foam exhibits an excellent apparent evaporation rate of ~2 kg/(m 2 ·h) and solar-to-vapor efficiency of ~91%. Here, the combined advantages of large surface area, high efficiency, low cost, all weather application, excellent durability, and scalable manufacturing make our integrated design promising for fabricating large-scale solar steam generation systems that are suitable for practical clean water production.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Computational Fluid Dynamics Simulations to Predict Oxidation in Heat Recovery Steam Generator Tubes

Heat Recovery Steam Generators (HRSGs) are widely used across United States in combined cycle power plants to recover waste heat from the gas turbine (GT). HRSGs are used either to generate electricity or to produce process steam for industrial applications. The primary components of HRSG consists of a duct and a heat exchanger (HX). It is known across the power industry that the high temperature oxidation and ensuing exfoliation problem is a major cause for the damage of HX materials of HRSG. Alloys and/or coatings that can prevent or mitigate oxidation are very expensive, therefore they must be used or applied on the select regions of the HX tubes where the tendency of oxide formation is the highest. The main goal of this project is to identify such regions through Computational Fluid Dynamics (CFD) simulations. Therefore, in this work, we developed a CFD framework using commercial code StarCCM+ for the prediction of the fluid flow and heat transfer in a HRSG and associated oxidation inside the tubes of the HX. The developed CFD framework was verified and validated with experimental data before deployment. We also developed an innovative method to model the effect of the fins on the heat transfer and the pressure drop using a porous media model (PMM) approach to keep the mesh size within reasonable limits. After validation, we performed high-fidelity CFD simulations of a real-scale HRSG using the PMM, with High Performance Computing (HPC) resources of ORNL. From the simulation results, we acquired oxide thickness maps for all the tubes of the select HX sections of HRSG prone to oxidation. These oxide maps can inform regions of the HX tubes that requires oxide-resistant coatings, thereby guiding engineers for cost-efficient manufacturing of the HX that can combat oxidation in HRSGs.

36 MATERIALS SCIENCE↗
DOE OSTI2016

Thermal hydraulic issues of HTGR helical tube once through steam generator: methods and applications - 18478

High Temperature Gas-cooled Reactor (HTGR) usually uses helical tube once through steam generators (OTSG) for steam generation. The most concerned thermal hydraulic issues of HTGR helical tube OTSG are two phase flow instability and temperature non-uniformity. One dimensional transient code and two dimensional code are developed to investigate these two issues. The codes are briefly introduced, then the results are briefly presented and discussed. The main conclusions are that there does not appear two phase instability for all the working conditions for the steam generator of HTR-PM. Tube plugging can introduce temperature non-uniformity in the tube bundle. The temperature non-uniformity can be evened by changing the flow rate distribution through adjusting the throttle orifice at the inlet. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2023

Computational fluid dynamics investigations of flow, heat transfer, and oxidation in heat recovery steam generator

Modern heat recovery steam generators (HRSGs) operate at elevated temperatures, leading to the formation of oxides inside the tubes of heat exchangers (HXs). This oxide growth reduces the heat recovery efficiency. Moreover, after reaching a certain critical thickness, some oxide scales detach from the tube surface (exfoliation), causing erosion damage to the components downstream. Predicting the metal temperature distribution and associated oxide thickness in the HXs of an HRSG can aid in mitigating these problems. Here, a computational fluid dynamics (CFD) model was developed within the commercial code STAR-CCM+ for the prediction of fluid flow, conjugate heat transfer, and associated oxidation in HRSGs. Moreover, a new Porous Media Model (PMM) method was developed to model the fin effect on the heat transfer in HX, which can substantially reduce the prohibitive computational costs of fin meshes. The developed CFD model was used to conduct a high-fidelity simulation of a real-scale HRSG to investigate flow, heat transfer, and oxide growth. The calculated oxide thickness on different tubes can be used to identify HX regions that require oxide-resistant coatings to prevent exfoliation and ensuing damages. Furthermore, this CFD framework can serve as a reference for future studies that intend to model and investigate high-temperature oxidation in HXs used for any applications.

42 ENGINEERING↗
DOE OSTI2018

Heat-and-Mass Transfer Intensification in Saturated-Steam Generators in NPP with VVER as a Means for Increasing Efficiency and Reliability

The intensification of steam generation in combination with improvement of the temperature regime, specifically, with the elimination of temperature fluctuations of the loaded components of the apparatus (heat-exchange tubes, warming-medium headers) increases the steam-generation capacity and eliminates the factors causing damage to the structural elements of steam generators. The possibility of intensifying heat-and-mass transfer on the basis of the experience gained in operating steam generators in NPP with VVER (horizontal) and NPP in foreign countries (vertical) is examined. It is concluded on the basis of the analysis that it is expedient to develop a domestically produced apparatus of the vertical type, which will make possible well-founded production of steam generators for NPP with VVER in the future.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2016

Pressure Drop-Flow Rate Curves for Single Phase Steam in Steam Generator U-tubes During Severe Accidents

Thermally induced steam generator tube rupture (TI-SGTR) can occur in pressurized water reactors (PWRs) with U-tube steam generators (SGs) during high pressure severe accident sequences resulting in containment bypass. Robust natural circulation patterns including in-vessel natural circulation and countercurrent flow to and from the SGs of superheated steam and other hot gases heats cooler structures in the reactor coolant system (RCS). The buoyancy driven flows return cooler and denser gases back to the core slowing the progression of some core degradation phenomena and failure of the lower head. As much as 50 percent of the decay energy and energy produced from core degradation oxidation reactions can be transported from the core to SGs resulting in the heat up and thermal creep of RCS pressure boundary components including hot leg nozzles, pressurizer surge line, and the SG tubes, many of which contain flaws. The creep failure of an individual tube is dependent on the transitory heating of the tube, a function of the mass flow rate through the tube and local temperature history of steam entering the tube. Buoyancy driven natural circulation flow rates are determined by changes in gravitational head, a combination of changes in fluid density due to heat transfer and change in elevation, and irreversible pressure drops resulting primarily from friction loss in the flow paths and other form losses. The nonuniform flow distribution in U-tubes of varying lengths and heights during single-phase liquid and two-phase natural circulation has been extensively studied in scaled test facilities and verified numerically in previous works. We hypothesize the countercurrent natural circulation of single-phase superheated steam in U-tube SGs is governed by the same characteristic pressure drop-flow rates curves of single-phase liquid and two-phase natural circulations in U-tubes connected to common plena derived in. Secondly, we propose flow distribution is a function of U-tube geometry - height, length, hydraulic diameter, etc., and the larger SGs of Combustion Engineering (CE) style 2 x 4 PWRs, which are the focus of this study, will show greater nonuniformity in tube by tube flow rates and ratio of forward flowing tubes to reverse flowing tubes. This work derives characteristic pressure drop-flow rate curves for single-phase superheated steam in CE-type SGs during a high pressure station blackout (SBO) sequence with failed auxiliary feedwater (AFW) and dry secondary side which is closely related to the TI-SGTR event. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2019

Porphyrin Covalent Organic Framework (POF)-Based Interface Engineering for Solar Steam Generation

Through replacement of traditional energy sources with sunlight as the heat source, solar steam generation has emerged as a promising technology for water purification and residuals management. Despite significant efforts to develop efficient photothermal materials for solar steam devices, challenges associated with scalable fabrication of high-performance materials remain. Moreover, most existing methods cannot be easily engineered to produce steam-generating devices with both arbitrary control over shape and high photothermal efficiency. Herein, a flexible porphyrin organic framework (POF)-based interface engineering method is introduced to produce high-performance solar steam generators. POFs, a recently discovered class of materials, are demonstrated to grow readily on a diverse range of porous substrates, including membranes, fabrics, sponges, and wood. Wood@POF exhibits particularly strong performance, achieving approximate to 80% light-to-steam conversion efficiency. This study demonstrates a universal, simple, and scalable interface engineering strategy for the fabrication of solar steam generators based on POF materials.

36 MATERIALS SCIENCE↗