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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.

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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Sustainble dropwise condensation enabled ultraefficient heat pipes

Heat pipes play a critical role in determining the operations, safety, and energy efficiency of electronics. The main focus to improve the heat pipe performance is on the evaporator design or wicking structures. However, the intrinsic limitation comes from the condenser, which is fundamentally constrained by inefficient filmwise condensation (FWC). In this study, we successfully achieved a peak effective thermal conductivity (k eff ) of ~140 kW/(m·K) on widely used groove heat pipes by implementing sustainable dropwise condensation (DWC) and integrating with enhanced evaporator. To better understand the working mechanisms of the ultraefficient heat pipe, both the evaporator and condenser of the heat pipes have been modified accordingly. Our results show that up to 296% enhancements on the k eff can be achieved under various inclination angles by only inducing DWC in the condenser section. The drawback of temperature fluctuations induced by DWC in smooth heat pipes appears to be effectively solved using the grooves-wicking structure. Furthermore, by integrating the nanostructured evaporator, the k eff of the heat pipe can be boosted up to 517% compared to conventional groove heat pipes. This study, for the first time, demonstrates the huge potential of engineering both the condenser and evaporator simultaneously in developing ultraefficient heat pipes.

42 ENGINEERING↗
DOE OSTI2025

Evaporator Temperature Transient Testing of a High-Performance Sodium Filled Heat Pipe

Heat pipes are two-phase heat transfer devices that enable passive removal of heat from the reactor core to the power conversion system in heat pipe-cooled microreactor designs. Experimental investigations of heat pipe transients are needed for technology demonstration, verification and validation of numerical codes, and the establishment of regulatory requirements. The Single Primary Heat Extraction and Removal Emulator (SPHERE) facility at Idaho National Laboratory (INL) serves as a platform for evaluating the dynamic response of high-temperature heat pipes under a variety of operating conditions. The present work details the experimental investigation of a high-performance, defined as over 2 kW sodium heat pipe subjected to rapid input power fluctuations induced by sudden changes in the evaporator temperature setpoint. In addition, the heat pipe was subjected to an asymmetrical heat load where a subset of heaters operated at 30% and 70% below their nominal power. These experimental conditions were chosen to simulate thermal and operational stresses expected to be encountered in microreactors to provide data on heat pipe behavior during such important transient events. Key data and performance metrics, including time series of temperatures and strains, axial temperature profiles, thermal response times, and heat transfer capabilities, the thermal output over thermal input, were reported and discussed. The results highlight the resilience of heat pipes, revealing their potential to maintain thermal stability and efficiency under varying power loads. Lastly, the paper concludes with a discussion on the significance of the results and their implications for future research.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Phenomena Identification and Ranking Table (PIRT) for heat pipes

Heat pipes are advanced passive thermal management devices that utilize phase change and capillary action to achieve efficient heat transfer. However, due to the complexity of the phenomena coupled in heat pipes, including capillary, phase change, turbulence, and compressibility effects, there are high uncertainties in the predictability of their operational regimes and performance. This PIRT exercise, conducted as a collaborative effort involving the Department of Energy (DOE) Microreactor Program (MRP), the Nuclear Regulatory Commission (NRC), and university partners systematically identifies, reviews, and prioritizes critical phenomena affecting the operation of heat pipes based on their importance and knowledge levels. Additional analyses and discussion are provided for phenomena with high importance and low knowledge, such as wick de-wetting, critical heat flux, contact angles, and pressure dynamics. The discussions included the recognizing challenges and proposing future research directions for both modeling and simulation and experimental efforts. Additionally, the report addresses phenomena with medium importance and low knowledge that could impact heat pipe operation during non-normal or transient operation, including frozen startup, laminar to turbulent transition, geyser boiling, wick priming, underfilling conditions, surface roughness of the wick, NCGs trapped in the wick, and the timescales of startup and shutdown. In conclusion, this comprehensive evaluation serves as a valuable resource for guiding future research and development efforts, supporting the successful integration of heat pipes into critical applications such as nuclear reactors, and contributing to the advancement of heat pipe technologies in safety-critical industries.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗
DOE OSTI2025

Studies of the influence of heat pipe model and coupling strategy in heat pipe microreactor simulations using Sockeye

This work demonstrates various modeling approaches for thermally coupling heat pipes to a graphite monolithic block in a microreactor context, accounting for the presence of a gap. We show that heat pipe model selection has a significant impact on the transient behavior of a three-dimensional coupled microreactor assembly problem by comparing results obtained using different heat pipe models from the heat pipe code Sockeye. Additionally, we show that the choice of coupling strategy has significant consequences for both accuracy and performance. Furthermore, we found that our heat flux transfer strategy exhibited greater accuracy than our temperature transfer strategy, even when comparing a loose coupling of the heat flux transfer strategy to a tight coupling of the temperature transfer strategy. Although this research uses only theoretical test problems, it provides important insights in modeling thermal fluids phenomena in heat pipe microreactors.

Direwolf↗
DOE OSTI2023

High-Fidelity Modeling and Experiments to Inform Safety Analysis Codes for Heat Pipe Microreactors

Heat pipe microreactors are reactor designs that primarily use liquid-metal heat pipes to cool the core. The main interest in heat pipes is the fact that they can remove heat passively. This, along with the use of liquid metal, allows the reactor to operate at higher temperatures. Although the use of heat pipes in nuclear reactors is new, liquid-metal heat pipe technology is mature. Nevertheless, experimental data on heat pipes are scarce, and very little is known about their behavior during abnormal operations and close to their thermal limits. Therefore, new experiments and accurate heat pipe simulations are needed to develop reliable closure models. This work describes a joint experimental and numerical investigation into heat pipes that attempts an initial closure of this gap. Further, the numerical and experimental efforts are currently proceeding in parallel, aimed at different aspects of heat pipes. The numerical part is focused on gaps in local closures, and the experiments capture the overall heat pipe behavior.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2019

Initial Evaluation of Nek-2P for Modeling of Liquid Metal Heat Pipes

A heat pipe is two-phase heat transfer device which relies on surface tension and capillary pressure to provide a very efficient heat transfer mechanism. Currently, there is interest in designing micro nuclear power reactors using high temperature heat pipes to provide totally passive cooling. To support this, heat pipe simulation capabilities must be developed. The spectral element multiphase CFD code, Nek-2P is being considered for use in providing high-fidelity results which will drive the development of reduced order models. This work is focused on an initial evaluation of the capabilities of Nek-2P to meet this goal. The two-fluid model is used in Nek-2P along with a set of closure models formulated for simulating heat pipes. Specifically, an interfacial force modeling the surface tension effect in the pores of the wick is included. Initial simulations using this model have been performed for conditions approaching nominal values for a sodium heat pipe. Nek-2P is able to qualitatively reproduce the expected results for the volume fraction, velocity, and pressure distributions with reasonable results for the phasic temperatures. This indicates the viability of using Nek-2P to perform more in-depth investigations. However, significant quantitative differences are noted between results and conditions typical of a sodium heat pipe. These differences in results are expected to diminish as the differences between the simulated conditions and the target conditions decreases. Additionally, challenges in simulating heat pipes with Nek-2P have been identified. Future work will focus on addressing these challenges and performing investigations of the operational limits of sodium heat pipes.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

A CONDUCTION-BASED HEAT PIPE MODEL FOR ANALYZING THE ENTIRE PROCESS OF LIQUID-METAL HEAT PIPE STARTUP

The Heat Pipe-cooled Microreactor (HPM) is one of the micro nuclear reactor designs under active study at the U.S. Idaho National Laboratory. Among the major concerns of HPM research is to understand the startup behavior of the heat pipe-cooled system associated with the startup of the liquid-metal heat pipes initialing from frozen state. The startup of liquid-metal heat pipes typically involves a number of nonlinear mass and heat transport processes including the phase change from solid to liquid and vapor. Hence, it is still a huge challenge to simulate the liquid-metal heat pipe startup using conventional CFD methods and software. The major difficulties of numerical CFD modeling come from the phase-change process, multiphase interaction, microporous wick flow, and compressible gas dynamics that occur during startup of the liquid-metal heat pipes. This paper proposes a simplified conduction-based method to provide practical insights into the entire startup process of the liquid-metal heat pipes while mitigating the challenges of addressing all the complex physics. We discuss the theoretical basis and modeling assumptions to analyze the liquid-metal heat pipe startup from frozen state based solely on heat-conduction equations. Then, the proposed model is implemented into the commercial CFD software to verify the model performance. The model prediction results are discussed via the comparison with the experimental data obtained from sodium heat-pipe startup experiments.

42 ENGINEERING↗
DOE OSTI2018

Heat pipe augmented passive solar heating system

A heat pipe augmented passive solar space heating system modulates the temperature inside a building structure, particular during heating seasons when the ambient temperature is below levels customarily associated with adequate room comfort, and in some embodiments comprises a solar absorber, a heat pipe surrounding wholly or partially by insulation, the heat pipe having three main sections which are an evaporator at one end proximal to the solar absorber, a condenser at the other end proximal to an interior room being heated, and a rubber adiabatic section between those. Additional aspects such as a mechanical valve in the adiabatic section are disclosed to limit unwanted thermal gains when cooling is needed because the ambient temperatures already exceed room comfort.

14 SOLAR ENERGY↗
DOE OSTI2021

Heat pipe reactor core and heat exchangers formation and deployment

A heat pipe reactor may include a reactor core and one or more heat exchangers positioned on one or both sides of the reactor core. The heat pipe reactor may also include a plurality of heat pipes extending from the reactor core and out through the one or more heat exchangers. The reactor core may be composed of a plurality of monolithic blocks.

Reid, Robert Stowers↗
DOE OSTI2022

Thermal Management System for an Electric Machine with Additively Manufactured Hollow Conductors with Integrated Heat Pipes: Preprint

This paper discusses steps taken to size a thermal management system for an aircraft propulsion electric machine containing additively manufactured coils integrated with heat pipes aimed at boosting its specific power. Experimental setups are used to size and characterize heat pipes for the application and 3D thermal FEA is used to determine optimum heat transfer coefficient of convective boundaries. Geometric details of fin-based surface area enhancement required to reach target combined overall heat transfer coefficient (U) and surface area (A) performance (UA) in W/K, is worked out for relevant boundaries and the resulting UA is verified in 3D thermal FEA. Thermal management system's UA (by extension specific power) sensitivity to coolant temperature is explored and temperature distribution plots of optimized machine components are presented and discussed.

additive manufacturing↗
DOE OSTI2023

The Use of the High-density UN Fuel in Heat-pipe Microreactors

Heat-pipe microreactors (HPMRs) are very small-scale nuclear reactors that employ heat pipes for heat removal. HPMRs can be easily integrated with other forms of renewable energies, used for emergency responses to disaster relief zones, deployed in remote locations not connected to the grid, and removed from sites and replaced by new ones. HPMRs can also be used for space missions as heat pipes do not rely on gravity for heat transfer. Conventional fuel materials, such as UO 2 and UCO, are currently considered in most existing HPMR designs, but ceramic UN fuel that has high uranium density, high thermal conductivity, and a high melting point may become a better fuel candidate.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2026

Dynamic modeling of heat pipe integrated thermal battery latent heat storage system experiment validation

A heat pipe integrated thermal battery system has been constructed to investigate a high-temperature latent heat thermal energy storage technology that takes advantage of near isothermal operation of latent heat storage and heat pipes to potentially enable high-energy isothermal heat storage. A dynamic model constructed in Modelica has been validated, showing errors between 2.5 °C–39.7 °C across 10-h to 47-h simulations against experiment results, showing good prediction capability of experiment output, especially against phase change time. Model calibrations showing vessel heat-up capability of 3 kW and heat pipes combining to provide 600 W each during experiment operation validate experiment circumstances including reduced material loading and reduced power capability. The experiment configuration uses an Al-Mg-Zn eutectic metal as the storage material, heated via heat tape wrapped around the vessel and guide tubes to bring the system to operation range (>400 °C) and to simulate charging heat exchange, respectively, with heat rejection occurring through the surfaces of the material and facilitated via guide tubes with less insulation wrapping. The model is available in the open-source repository HYBRID on Github.

25 - ENERGY STORAGE↗
DOE OSTI2023

A novel 3-D pulsating heat pipe module for high heat-flux applications

This study proposed a novel pulsating heat pipes (PHP) for high-flux thermal module. According to the open literature, the maximum value of the heat flux is 23.7 W∙cm –2 handled by PHP, which is far behind industry requirements. Therefore, the present study proposes a novel 3D PHP suitable for high heat-flux applications. The PHP were experimentally tested for different working fluids, including methanol and water. Furthermore, the experiments were performed to analyze the influence of various operating parameters, such as filling ratio (25–60%), heat load (100–800 W), and air flow rate 100–250 cubic feet per minute (CFM). In this work, the results showed that this PHP can sustain a heat flux up to 70 W∙cm –2 with the maximum case temperature under 80 °C, which is approximately three times higher than the available literature. Furthermore, the performance of the PHP module was compared against the commercial module with wicked heat pipe. The PHP exhibited about 7% higher heat dissipation compared to the commercial module. Since the proposed module uses simple copper tubes in its construction over the wicked structure used in commercial module, the novel 3D PHP module provides additional economic and mass production capability.

3D pulsating heat pipe↗
DOE OSTI2024

The Use of High-Density UN Fuel in Heat-Pipe Microreactors

Heat-pipe microreactors (HPMRs) are very small-scale nuclear reactors that employ heat pipes (HPs) for heat removal. HPMRs can be easily integrated with other forms of renewable energies, can be used for emergency responses to disaster relief zones, can be deployed in remote locations not connected to the grid, and can be removed from sites and replaced by new ones. HPMRs can also be used for space missions as HPs do not rely on gravity for heat transfer. Conventional fuel materials, such as uranium oxide (UO 2 ) and uranium oxycarbide (UCO), are currently considered in most existing HPMR designs, but ceramic uranium nitride (UN) fuel that has high uranium density, high thermal conductivity, and high melting point may become a better fuel candidate. Through neutronics calculations, this paper assesses the impact of using UN fuel in HPMRs with two different neutron spectra (fast and thermal) and two different fuel forms [traditional solid fuel pellets and TRi-structural-ISOtropic (TRISO) fuel compacts]. It was concluded that retrofitting HPMRs with UN fuel has the potential to reduce the initial 235 U enrichment requirement by ~3 wt% (to keep the same cycle length) or increase the cycle length (by keeping the same initial 235 U enrichment), which enables more compact and transportable HPMR core designs. However, using UN fuel decreases the control element worth [by up to 20% for the Special Purpose Reactor (SPR) and 5% for HP-MR] and is up to 80% more costly. Increasing 15 N enrichment can further decrease the initial 235 U enrichment requirement and increase the control element worth but is more costly. In conclusion, compared to fast-spectrum HPMRs fueled with solid pellet fuels, retrofitting UN fuel is more suitable for thermal-spectrum HPMRs fueled with TRISO fuel compacts, where the neutron spectrum hardening caused by using UN is less significant.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2013

Neutron imaging of alkali metal heat pipes

High-temperature heat pipes are two-phase, capillary driven heat transfer devices capable of passively providing high thermal fluxes. Such a device using a liquid-metal coolant can be used as a solution for successful thermal management on hypersonic flight vehicles. Imaging of the liquid-metal coolant inside will provide valuable information in characterizing the detailed heat and mass transport. Neutron imaging possesses an inherent advantage from the fact that neutrons penetrate the heat pipe metal walls with very little attenuation, but are significantly attenuated by the liquid metal contained inside. Using the BT-2 beam line at the National Institute of Standards and Technology (NIST) in Gaithersburg, Maryland, preliminary efforts have been conducted on a nickel-sodium heat pipe. The contrast between the attenuated beam and the background is calculated to be approximately 3%. This low contrast requires sacrifice in spatial or temporal resolution so efforts have since been concentrated on lithium (Li) which has a substantially larger neutron attenuation cross section. Using the CG-1D beam line at the High Flux Isotope Reactor (HFIR) of Oak Ridge National Laboratory (ORNL) in Oak Ridge, Tennessee, the first neutron images of high-temperature molybdenum (Mo)-Li heat pipes have been achieved. The relatively high neutron cross section of Li allows for the visualization of the Li working fluid inside the heat pipes. The evaporator region of a gravity assisted cylindrical heat pipe prototype 25 cm long was imaged from start-up to steady state operation up to approximately 900 C. In each corner of the square bore inside, the capillary action raises the Li meniscus above the bulk Li pool in the evaporator region. As the operational temperature changes, the meniscus shapes and the bulk meniscus height also changes. Furthermore, a three-dimensional tomographic image is also reconstructed from the total of 128 projection images taken 1.4o apart in which the Li had already cooled and solidified.

heat pipe↗
DOE OSTI2020

Thermocatalytic Heat Pipes for Geothermal Resource Recovery

Heat pipes are an important technology that allow orders of magnitude faster heat transfer than simple conduction. However, operating principles in heat pipes place fundamental bounds on their performance (critical heat flux and efficiency). Conventional heat pipe functionality is inherently tied to vaporization and condensation of the working fluid charged in the heat pipe. These fluids each have different operating temperature ranges based on the capillary, entrainment, sonic, and boiling limits of the heat pipe design. These limits, typically the capillary limit, dictate the maximum heat flux a heat pipe can carry, and most importantly for geothermal systems, the distance over which the pipes can operate (100 to 200 m maximum under optimum conditions). A thermocatalytic heat pipe breaks the inherent limitations of phase change thermo- and hydrodynamics and can transform heat pipe technology as a potentially more efficient means of extracting heat from a geothermal resource. The thermocatalytic heat pipe uses a working fluid to transport both sensible and chemical heat. An endothermic chemical reaction at depth removes heat from the reservoir and produces reactive intermediates, which are transported to the surface and used to run a reverse exothermic reaction that releases heat for use in power generation or other useful purposes. This technology offers two distinct advantages over conventional geothermal heat recovery technologies: (1) lower heat loss to the rock outside of the geothermal reservoir, and (2) higher heat transfer rates to the well field within the geothermal reservoir. Both advantages offer opportunity to reduce risks and lower costs of geothermal energy recovery. In this report, we discuss an initial effort to assess the efficacy and limitations of this technology for extracting heat from both porous/permeable and nominally impermeable geothermal reservoirs. Numerical simulation capabilities of the STOMP-GT code were enhanced to enable simulations of thermochemical heat pipes traversing geothermal reservoirs. An array of potential thermochemical reaction systems was evaluated and screened. Of these, an ethanol dehydration reaction was most promising in the vapor-liquid reaction set. A solid-phase dehydration reaction (CuSO4·5H2O) showed the highest reaction enthalpy per unit volume but would require development of a nonaqueous carrier fluid to implement it in a heat pipe. Subsurface reservoir simulations predicted long-term performance of the heat pipes for each geothermal reservoir type. The performance of U-shaped wells and coaxial wells was evaluated for a suite of reactions for both hydrothermal and hot dry rock reservoirs and was compared with a baseline case of simply pumping water through the wells. The heat pipe technology was additionally evaluated for an enhanced geothermal system (EGS) with an injection borehole, production borehole, and intervening hydraulically conductive fracture. All reservoir types showed significant improvement in heat recovered over a 20-year operating period ranging from a 1.8X increase for the hot dry rock case to more than 2.5X more energy recovered for the EGS case.

15 GEOTHERMAL ENERGY↗
DOE OSTI2022

[Presentation Slides] Code-to-Code Benchmark Study for Thermal Stress Modeling and Preliminary Analysis of the High-temperature Single Heat-Pipe Experiment

In the heat-pipe-cooled microreactor, heat pipes remove heat from the reactor core as a passive heat-transfer device, so the fluid circulation is not required for cooling, which can substantially simplify the overall reactor design. However, given the extremely high temperatures in the core region and potentially large temperature gradients across the structure materials, thermal stresses need to be well-analyzed to ensure structural integrity during normal operations and accident scenarios. This presentation slides discuss finite element method-based thermal-stress analysis for the high-temperature single heat-pipe test article in the Single Primary Heat Extraction and Removal Emulator (SPHERE) facility at Idaho National Laboratory (INL), using two commercial software packages, Abaqus and Star-CCM+. A code-to-code benchmark study was performed to crosscheck the model setup and capability of each code and to gain preliminary insights into the potential thermal stress concerns from the current experimental setup. It is observed the significant thermal stresses happen at the inner surface of the heat pipe hole surrounded by electric heaters where the largest temperature gradients appear. The temperature fields have good agreements between Abaqus and Star-CCM+, while the induced thermal stresses show modest deviations probably due to differences of meshing engines used in these two codes. It is found that the local maximum thermal stresses may reach close to the ultimate tensile strength and yield strength of structural material depending on the heater power. Ultimately, the coupled thermal-structural analysis will help guide the current experimental plan and ensure the facility safety for future experimental study.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗