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DOE OSTI2020

High-Temperature Heat Transfer Fluid Circulator for Concentrating Solar Power Systems

Concentrating Solar Power (CSP) plants with Thermal Energy Storage (TES), require compressors capable of circulating supercritical carbon dioxide (sCO2) heat transfer fluids (HTFs) at temperatures from 500 to 700+°C and pressures from 8 to 25 MPa (80 to 250 Bar or 1160 to 3626 psia) in order to achieve thermal-to-electric efficiencies >50%. A review of papers relating to SCO2 compressors reveals that in almost every case the conditions being considered either allow for cooling of the SCO2 working fluid or are considering operating conditions close to the critical point at a temperature and pressure of approximately 31°C and 1070 psi). While the technology reported in these papers is relevant to most turbomachinery, the current CSP gas pathway circulator operating pressures are well above the CO2 critical point and do not allow for cooling of the main HTF flow. The purpose of this paper was to describe the key system issues affecting the design of a HTF circulator that could be scaled from a small size research and proof of concept circulator compressor to sizes supporting power plants producint upwards of 100 to 300 Mega Watts of electrical power. Due to the high temperatures and pressures the research scale HTF circulator was designed to be hermetically sealed to prevent leakage of the super critical carbon dioxide to the environment. In order to achieve hermetic sealing the drive motor and centrifugal impeller were fully integrated in a single shaft system configuration. From a preliminary assessment of compression power as a function of operating speed and impeller diameter it was determined that a smaller, higher speed impeller would result in a more efficient circulator. However, due to the high pressure and corresponding density of the sCO2 coupled with high operating speeds, large windage losses (i.e., viscous drag on the high speed rotating shaft) would occur which could result in a substantial reduction in efficiency of the system. Therefore tradoff studies were complerted to identify the operating speeds and system component sizes to achieve high efficiency. Based on the trade studies, the final design was a 55 mm diamter compressor impeller operating at speeds to 85,000 rpm. The unit will be built and tested in the future. Key Words: Super Critical Carbon Dioxide, Heat Transfer Fluid, Turbomachinery, Compressor, Circulator, Critical Point, Concentrating Solar Power, Solar Energy

Super Critical Carbon Dioxide, Heat Transfer Fluid↗

DOE OSTI2020

Pumped Thermal Electricity Storage with Supercritical CO2 Cycles and Solar Heat Input

Pumped Thermal Electricity Storage (PTES) is an energy storage device that uses grid electricity to drive a heat pump that generates hot and cold storage reservoirs. This thermal potential is later used to power a heat engine and return electricity to the grid. In this article, a PTES variant that uses supercritical carbon dioxide (sCO2) as the working fluid is introduced. sCO2-PTES cycles have higher work ratios and power densities than the systems based on ideal gases that have been investigated to date. Furthermore, sCO2- PTES cycles may achieve higher round-trip efficiencies for a given hot storage temperature (up to 78% at 560°C). The sensitivity of PTES cycles to loss factors such as isentropic efficiencies and temperature differences between the power cycle and storage fluid is investigated. A second concept whereby an sCO2- PTES cycle is integrated with concentrating solar power (CSP) is introduced. This concept ‘time-shifts’ the recompression of an sCO2 recompression cycle to a period of lower electricity prices and stores the heat. When solar heat is dispatched, the recompressor may be avoided as the required heat is obtained from storage, thereby leading to increased heat engine efficiencies. The net work output of this integrated system is 10-18% greater than the conventional recompression cycle. Combining PTES with a CSP power cycle is therefore shown to improve the dispatch of solar heat as well as providing electricity storage services.

41 EE - Solar Energy Technologies Office (EE-4S)↗

DOE OSTI2020

Measurements of Density and Sound Speed in Mixtures Relevant to Supercritical CO2 Cycles

Abstract The objective of this research is to validate properties of mixtures relevant to supercritical carbon dioxide (sCO2) power cycles. Direct-fired sCO2 cycles are a promising technology for the future power generation systems. The working fluid of sCO2 cycles will be near and above critical point of CO2. One of the challenges is that the simulation of mixtures should consider real gas behavior. Expected operating conditions of Allam cycles reach up to 300 bar and 1000 °C. Characterizing the mixtures at the extreme conditions is an important issue in current researches and industrial applications. Thermophysical properties of mixtures may be beyond the valid range of the widely used database such as NIST REFPROP. Experimental data of mixture properties in the literature are limited which is necessary to develop high-fidelity design tools for sCO2 power cycles. We measured the density and sound speed of several multi-component mixtures. A temperature-controlled high-pressure test cell was used for the density measurements. Sound speed was measured by resonant frequency detection using an external speaker and a piezoelectric pressure sensor. Mixtures studied in this work include carbon dioxide, methane, oxygen, and water vapor. Properties of pure CO2 were measured to show the validity of our technique. Compositions were selected to be close to frozen mixtures at the inlet, mid-progress, and exhaust conditions of a model sCO2 combustor in the previous numerical simulation work. Corresponding reaction progress variables (RPV) were RPV = 0, 0.5, and 1. Temperature and pressure conditions of experiments are 310–450 K and 0–150 bar. In our study, density and sound speed from the NIST REFPROP database agree with experimental measurements within the range of our measurement uncertainties.

Energy & Fuels↗

DOE OSTI2023

Closed Loop Geothermal Working Group: GeoCLUSTER App, Subsurface Simulation Results, and Publications

To better understand the heat production, electricity generation performance, and economic viability of closed-loop geothermal systems in hot-dry rock, the Closed-Loop Geothermal Working Group -- a consortium of several national labs and academic institutions has tabulated time-dependent numerical solutions and levelized cost results of two popular closed-loop heat exchanger designs (u-tube and co-axial). The heat exchanger designs were evaluated for two working fluids (water and supercritical CO2) while varying seven continuous independent parameters of interest (mass flow rate, vertical depth, horizontal extent, borehole diameter, formation gradient, formation conductivity, and injection temperature). The corresponding numerical solutions (approximately 1.2 million per heat exchanger design) are stored as multi-dimensional HDF5 datasets and can be queried at off-grid points using multi-dimensional linear interpolation. A Python script was developed to query this database and estimate time-dependent electricity generation using an organic Rankine cycle (for water) or direct turbine expansion cycle (for CO2) and perform a cost assessment. This document aims to give an overview of the HDF5 database file and highlights how to read, visualize, and query quantities of interest (e.g., levelized cost of electricity, levelized cost of heat) using the accompanying Python scripts. Details regarding the capital, operation, and maintenance and levelized cost calculation using the techno-economic analysis script are provided. This data submission will contain results from the Closed Loop Geothermal Working Group study that are within the public domain, including publications, simulation results, databases, and computer codes. GeoCLUSTER is a Python-based web application created using Dash, an open-source framework built on top of Flask that streamlines the building of data dashboards. GeoCLUSTER provides users with a collection of interactive methods for streamlining the exploration and visualization of an HDF5 dataset. The GeoCluster app and database are contained in the compressed file geocluster_vx.zip, where the "x" refers to the version number. For example, geocluster_v1.zip is Version 1 of the app. This zip file also contains installation instructions. **To use the GeoCLUSTER app in the cloud, click the link to "GeoCLUSTER on AWS" in the Resources section below. To use the GeoCLUSTER app locally, download the geocluster_vx.zip to your computer and uncompress this file. When uncompressed this file comprises two directories and the geocluster_installation.pdf file. The geo-data app contains the HDF5 database in condensed format, and the GeoCLUSTER directory contains the GeoCLUSTER app in the subdirectory dash_app, as app.py. The geocluster_installation.pdf file provides instructions on installing Python, the needed Python modules, and then executing the app.

15 GEOTHERMAL ENERGY↗

DOE OSTI2022

Creep and Fatigue Characterization of High Strength Alloy Thin Sections in Advanced CO2 Heat Exchangers

The objective of this work was to characterize and model elevated temperature creep and fatigue behavior for thin sheet and foil forms of gamma-prime strengthened alloys in wrought form and as-processed folded and brazed constructions. This work was motivated by the demanding temperature and pressure service conditions of the GEN3 Concentrated Solar Power (CSP) and supercritical CO2 (sCO2) power cycle working fluid. More specifically, the possibility of leveraging the superior creep strength of gamma-prime alloys in folded-fin and brazed-plate heat exchanger constructions. Gamma-prime alloys represent a step-change in raw-material strength over solid-solution strengthened alloys. And the folded-fin and brazed-plate heat exchanger architecture is lightweight and leverages cost-effective material stock forms. The investigation contained two parallel paths. (1) The first is referred to as a fundamental investigation where Oak Ridge National Laboratory conducts uniaxial creep testing on thin sheet and foil in wrought form. This effort aimed to serve as a benchmark against a relatively sparse existing database and a baseline comparison for path number 2. (2) The second path is referred to as the practical investigation where Brayton Energy manufactures plate-fin heat exchangers and performs pressurized creep and fatigue testing. This effort aimed to de-risk heat exchanger manufacturing process for service under sCO2 CSP conditions. A total of 14 uniaxial creep tests were completed using Haynes 282 thin sheet and foil. A variety of heat treatments were specified to coincide with path number 2. Baseline metallography of test samples and creep strength performance are contained. Benchmarks relatively to existing thick-form Haynes 282 are made, as well as to other thin-form Nickel-based superalloys. Description of a wrought-form modeling approach for thin gamma-prime alloys is also discussed. A total of 11 pressurized creep and fatigue tests were completed successfully with Haynes 282 heat exchanger prototypes. Manufacturing processing details, testing details, testing results, and failure analysis are discussed. Additionally, creep modeling techniques to predict failure are discussed, and modeling to support technological-to-market. In conclusion, Haynes 282 foils were demonstrated to yield rupture two-to-three orders of magnitude higher than Haynes 230 foils under similar conditions. And the manufactured heat exchanger prototypes demonstrated strength similar to the wrought constituents. Both of which contribute to elevated performance potential or cost savings in practice. Discussion is included.

14 SOLAR ENERGY↗

DOE OSTI2026

Development of Novel Combustion Codes for Supercritical CO2 Combustion: Cooperative Research and Development Final Report, CRADA Number CRD-20-17182

The Allam-Fetvedt Cycle, a novel supercritical CO2 (sCO2) power cycle developed by 8 Rivers Capital, LLC, generates low-cost power from fossil fuels while capturing combustion-CO2. This cycle employs high-temperature oxy-combustion using sCO2 as the working fluid, leading to a challenging environment for materials. The most critical component for reliable deployment of this technology is the combustor-turbine interface. In the proposed partnership between NREL and 8 Rivers, we will develop a simulation-based tool to provide key design inputs for defining the materials and geometries required in this critical area.

09 BIOMASS FUELS↗

DOE OSTI2022

High-Fidelity Simulations of Supercritical CO2 Based Oxy-Combustion with Non-Ideal Equation of State

The supercritical carbon dioxide (sCO2) Allam-Fetvedt cycle employs high-temperature oxy-combustion using sCO2 as the working fluid, leading to a unique and challenging environment for materials. In this cycle, pressurized gaseous fuel is combusted in the presence of a hot oxidant flow containing a mixture of CO2 and oxygen and a hot CO2 diluent recycle stream at approximately 300 bar under lean combustion conditions. We present high-fidelity reacting simulations of this oxy-combustor environment and compare the results when performing simulations with ideal and non-ideal equations of state. By doing so, we identify if the combustor behavior at the regime of interest is sensitive enough to the equation of state to justify the added computational cost incurred with a non-ideal equation of state.

equation of state↗

DOE OSTI2022

Supercritical CO2 Heat Pumps and Power Cycles for Concentrating Solar Power

Pumped Thermal Energy Storage (PTES) is a promising technology for electricity storage applications. An electrically driven heat pump moves energy from a cold space to a hot space, thereby creating hot and cold thermal storage. The temperature difference between the hot and cold storage is later used to drive a heat engine and return electricity to the grid. In this article, supercritical carbon dioxide (sCO2) is chosen as the working fluid for PTES, and results are compared to 'conventional' systems that use nitrogen. Molten salts are used for the hot storage which means that a CSP plant with thermal storage and an sCO2 power cycle could potentially be hybridized with PTES by the addition of a heat pump. This article describes some of the benefits of this combined system which can provide renewable power generation and energy management services. Two methods by which an sCO2 heat pump can be combined with an sCO2 power cycle for CSP are described and techno-economic results are presented. Results indicate that these systems can achieve reasonable technical performance, but that costs are currently high.

carnot battery↗

DOE OSTI2020

Supercritical CO2 Heat Pumps and Power Cycles for Concentrating Solar Power: Preprint

Pumped Thermal Energy Storage (PTES) is a promising technology for electricity storage applications. Grid electricity drives a heat pump which moves energy from a cold space to a hot space, thereby creating hot and cold thermal storage. The temperature difference between the storage is later used to drive a heat engine and return electricity to the grid. In this article, supercritical carbon dioxide (sCO2) is chosen as the working fluid for PTES, and results are compared to ‘conventional’ systems that use an ideal gas. Molten salts are used for the hot storage which means that a CSP plant with thermal storage and an sCO2 power cycle could potentially be hybridized with PTES by the addition of a heat pump. This article describes some of the benefits of this combined system which can provide renewable power generation and energy management services. Two methods by which an sCO2 heat pump can be combined with an sCO2 power cycle for CSP are described and techno-economic results are presented. Results indicate that these systems can achieve reasonable technical performance, but that costs are currently high.

41 EE - Solar Energy Technologies Office (EE-4S)↗

DOE OSTI2024

Verification and Validation of Spectral Element Code for Supercritical CO2 Flow in Vertical Heated Tubes

The investigation of heat transfer in supercritical CO2 (sCO2) has garnered considerable attention in recent decades, given sCO2's potential as a promising working fluid for advanced power conversion cycles. Despite previous research efforts, there are still gaps in our understanding of sCO2 heat transfer, particularly in conditions associated with heat transfer deterioration. To delve into sCO2 heat transfer more comprehensively, we propose employing the high-fidelity computational fluid dynamics code NekRS to simulate sCO2 flow using the large eddy simulation technique. Through graphics processing unit acceleration, NekRS achieves a higher computational speed than traditional CPU-based systems. However, before using NekRS in practical applications involving sCO2, it is imperative to perform verification and validation. Here, this paper presents our efforts to verify and validate the NekRS code's capability for simulating sCO2 using heated vertical tubes, where heat transfer deterioration usually happens. To accommodate the unique properties of sCO2, we have modified the NekRS code by integrating third-party property modules, such as REFPROP and PROPATH. Our simulations are compared with experimental and numerical data from the literature, instilling confidence in leveraging NekRS for future engineering applications. Our simulations also reveal that the accuracy of the property module significantly impacts the results, with REFPROP outperforming PROPATH for sCO2 properties. Additionally, we observed that, depending on the flow direction, buoyancy can either enhance or suppress turbulence in sCO2 flow. In upward flow, under certain conditions, the suppressed turbulence leads to heat transfer deterioration, resulting in elevated wall temperatures.

NekRS↗

DOE OSTI2024

Summary of Structural Alloy Compatibility in Supercritical CO2 at 450°-800°C

Supercritical CO2 (sCO2) is of interest as a working fluid for several concepts including the direct- fired Allam cycle as a low-emission fossil energy power cycle. Over the past 10 years, laboratory exposures at 300 bar sCO2 have found reasonably good compatibility for Ni-based alloys at <800°C, including an assessment of the sCO2 impact on room temperature mechanical properties after 750°C exposures. However, initial screening tests at 1 and 20 bar CO2 at 900°-1100°C showed poor compatibility for Ni-based alloys. In an open cycle, the introduction of 1%O2 and 0.1- 0.25%H2O impurities at 300 bar increased the reaction rates ≥2X at 750°C. At lower temperatures, steels are susceptible to C ingress and embrittlement. Creep-strength enhanced ferritic steels may be limited to <550°C and conventional stainless steels to <600°C. Two strategies to increase those temperatures are higher Ni and Cr alloying additions and Al- or Cr-rich coatings. Alloy 709 (Fe- 20Cr-25Ni) shows some promising results at 650°C in sCO2 but reaction rates were accelerated with the addition of O2 and H2O impurities. Pack aluminized and chromized Gr.91 (Fe-9Cr-1Mo) and type 316H stainless steel show some promise at 600°-650°C but further coating optimization is needed.

Pint, Bruce↗

DOE OSTI2021

Advancements Toward ASME Nuclear Code Case for Compact Heat Exchangers

Our research team proposes to advance the state of the ASME section III code (nuclear service) for Compact Heat Exchangers (CHX). This work will improve the technical state of CHXs and lay the foundation necessary for these heat exchangers to be certified for use in nuclear service. During the course of this work, we will advance the understanding of the performance, integrity, and lifetime of the CHXs for use in any industrial application, making their use more attractive and accessible to the industry. We will do this by developing qualification and inspection procedures that utilize Non-destructive evaluation (NDE) and advanced in-service inspection techniques, with insight from the industrial utility leader EPRI. We have enlisted colleagues at MPR Associates (MPR), an elite nuclear code consulting firm, who are experts on the ASME section III code and who, with input from members of the ASME section III committee, will direct the testing and help develop a series of documents that define the rules and regulations for use of the CHX. Colleagues at North Carolina State University (NCSU) and Oregon State University (OSU) will conduct extensive tensile, creep, and fatigue experiments on diffusion bonded samples (manufactured by US-based Vacuum Process engineering) along with modeling using the elastic perfectly plastic assumptions and comprehensive full inelastic finite element analysis (FEA). This work will allow analysis by design and confidence in the strength of different internal structures. To ensure industry acceptance and long term confidence, team members at the University of Wisconsin–Madison (UW), University of Michigan (UM), Georgia Tech (GT), and the University of Idaho (UI) will extensively test prototypic heat exchangers manufactured by US-based manufactures CompRex and Vacuum Process Engineering (VPE), a leader in the development of advanced CHX. This testing will include the use of various working fluids (salt, sodium, helium, and sCO2) to evaluate operational issues as well as structural integrity under the most severe conditions. Post-test analysis of the tested CHXs coupled with pre/in-service/post NDE (ultrasonic and radiography) led by the Electric Power Research Institute (EPRI) will be incorporated into the development of the rules and regulations for their use in nuclear service.

42 ENGINEERING↗

DOE OSTI2022

Experimental and Computational Heat Transfer Study of sCO2 Single Jet Impingement

The present study experimentally investigates the heat transfer capability of supercritical carbon dioxide (sCO2) single-jet impingement. The evaluated jet Reynolds number range is between 80,000 and 1,000,000, with a non-dimensional jet-to-target surface spacing of 2.8. CO2- impinging jet stagnation conditions were maintained at approximately 20 MPa and a temperature of 673 K for most experiments. The goal is to understand how changes in the aforementioned parameters influence heat transfer between the working fluid and the heated surface. Additionally, due to the elevated Reynolds numbers and difference in thermodynamic properties between air and CO2, air-derived impingement correlations may not be appropriate for CO2 impingement; these correlations will be evaluated against experimental sCO2 impingement data. At the time of this study, no sCO2 impingement data was available relevant to sCO2 power cycles. The target surface is a 1.5-inch diameter copper block centered on the 3mm jet orifice. A mica heating element bolted to the bottom of the copper block provides a uniform heat flux. Thermocouples embedded in the copper block are used to determine the surface temperature. Nusselt numbers obtained from experimental sCO2 data are compared to area-averaged Nusselt numbers from air-derived correlations. The comparisons showed that air correlations drastically underpredict the heat transfer when sCO2 is used as the working fluid. A modified sCO2 correlation using experimental data at discussed conditions is derived based on an existing air correlation.

Richardson, John↗

DOE OSTI2025

Computational and Experimental Investigation of Discrete “W” Turbulators for sCO2 Turbine Internal Cooling

Direct-fired supercritical CO2 (sCO2 ) cycles are of particular interest for power generation due to the potential for higher thermal efficiencies with inherent CO2 capture. Direct fired sCO2 turbines must withstand high temperatures and the density of the working fluid is much higher than conventional Brayton cycles. Based on conventional Brayton cycle applications, internal serpentine cooling channels with ribbed turbulator strips are a common approach to achieve the required cooling, while minimizing coolant utilization. Most of the previous studies of coolant channel heat transfer enhancements have focused on serpentine channels using air as the cooling media at Reynold’s numbers typical of Brayton cycles. This paper investigates the Nusselt number augmentation of coolant channels with no features, ribbed turbulators, and discrete “W” turbulators with surface roughness effects included and CO2 as the coolant. The numerical results are compared to experimental results using CO2 as the cooling media at Reynold’s numbers ranging from 100,000 to 300,000. The results show the Nusselt number augmentation plateaus with increasing Reynolds number, in contrast to the decay observed in prior publications with air as the coolant media. Additionally, the CFD results indicate the discrete “W” geometry provides a 10% increase in Nusselt number augmentation relative to the angled ribbed turbulators.

computational fluid dynamics (CFD)↗

DOE OSTI2022

Mechanically-, Thermally, and Chemically-Robust High-Temperature Ceramic Composites

In an effort to lower the levelized cost of electricity generated by Concentrated Solar Power (CSP) plants, the heat-to-electricity conversion efficiency may be increased by operating such plants with higher turbine inlet temperatures using closed Brayton cycles with high-pressure, supercritical carbon dioxide (sCO 2 ) as the working fluid. For example, if the turbine inlet temperature is raised to ≥750°C, in combination with sCO2 closed Brayton cycles, the relative heat-to-electricity efficiency may be raised by more than 20% (compared to subcritical steam Rankine cycles operating with turbine inlet temperatures ≤550°C). The associated reduction in the cost of dispatchable electricity from such CSP plants (utilizing high-temperature thermal energy storage) would be an important breakthrough on the path towards direct competition with fossil-fuel-based plants. A key barrier to achieve such high-temperature efficient operation has been the limited thermomechanical performance of metal alloys used in compact, primary printed circuit- type heat exchangers (PCHEXs) for heat transfer to high-pressure sCO 2 . The maximum allowed stresses for the use of conventional stainless steels and nickel-based superalloys at high sCO 2 pressures (≥20 MPa) decline rapidly at temperatures ≥550°C. This project has been focused on demonstrating the desired high-temperature properties and attractive manufacturing characteristics of mechanically-, thermally-, and chemically-robust ceramic/metal composites (cermets), in order to allow for the use of such composites in primary PCHEXs for heat transfer to sCO 2 at ≥750°C and ≥20 MPa in CSP plants. Prior work with high-temperature, co-continuous carbide/refractory metal cermets, such as ZrC/W composites, has already demonstrated: i) the attractive combination of high-temperature properties exhibited by such materials (e.g., high values of stiffness, failure strength, and thermal conductivity at 800°C), and ii) cost-effective processes for manufacturing PCHEX plates comprised of such cermets with tailorable channel patterns. However, ZrC/W cermets were not found to be inherently corrosion resistant in sCO 2 at 750°C and 20 MPa. While the application of a Cu coating to ZrC/W surfaces, along with a modest addition (50 ppm) of CO to CO 2 , rendered such composites resistant to corrosion for 1000 h in such sCO 2 -based fluids at 750°C, such additional steps would increase the design complexity of such cermet-based components. An alternative approach (the focus of this project) is to develop mechanically-robust, cost- effective cermets that are inherently resistant to high-temperature oxidation in air and CO 2 . The overall goals of this project have been to demonstrate: i) the oxidation resistance of at least one cermet at 750°C in air and in CO 2 (i.e., with a projected annual corrosion ≤30 μm), ii) the mechanically robust nature of at least one cermet at 750°C (i.e., with an average failure strength ≥200 MPa), and iii) that the selected cermet can be manufactured via low-cost forming techniques.

14 SOLAR ENERGY↗

DOE OSTI2020

Microreactor Agile Nonnuclear Experimental Testbed Test Plan

Microreactors are an attractive technology option for kick-starting nuclear innovation if they can be operated at high temperature, yielding high power conversion thermal efficiencies comparable or better than in commercial light water reactors. Microreactors are currently the smallest variation of Small Modular Reactors (SMRs). SMRs are “newer generation reactors designed to generate electric power up to 300 MWe and whose components and systems can be shop-fabricated and then transported as modules to the sites for installation as demand arises.” (IAEA, 2016). Vendors are developing microreactor designs to provide an affordable, potentially mobile source of electricity - see Fig. 1 for an example of a microreactor on a semi-truck. Various microreactor designs are possible including heat pipe- and gascooled options, which are the focus of the nonnuclear testing described in this document. In heat pipe microreactors, high-temperature heat pipes using liquid sodium or potassium working fluid transport fission heat from the core to a heat removal section which in turn transfers heat to the power conversion system working fluid. In a gas-cooled design, He or other gas will flow through a solid monolith of material and transfer heat as the temperature of the gas increases through a heat exchanger to a power conversion unit. The logistics of all these processes will be examined and tested through a series of articles at the nonnuclear test bed at Idaho National Laboratory (INL), the Microreactor Agile Nonnuclear Experiment Testbed (MAGNET) facility. Microreactors designed to produce power of 0.1-20 MWt offer the potential for more affordable nuclear energy for a range of applications. In a heat pipe microreactor, heat pipes, fuel rods, and/or moderator are intermixed in the reactor core assembly. Heat pipes extend from the core region into the heat removal section where the power conversion unit working fluid flows through holes or channels, transferring heat from the heat pipes to the working fluid. In a gas-cooled microreactor, gas flows through the solid monolith region and up into the heat exchanger region, transferring heat to the working fluid. For initial testing, the heat removal working fluid can be a low pressure gas for testing that addresses thermal stresses. In the final application, heat addition to the power conversion working fluid typically occurs at high pressure, supporting operation of an air-Brayton, supercritical CO 2 (SCO2), or He-recuperated Brayton cycle. Various stages of the steps above will be demonstrated through the tests described in this report.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2025

Experimental Investigation of Vapor Formation in Liquid CO2 Flow Through a Converging-Diverging Nozzle

Carbon dioxide is an attractive working fluid for many cycles, including for pumped thermal energy storage (PTES). A challenge with some proposed sCO2 PTES cycles is the operation of sCO2 machinery outside the typical bounds of experience, with local phase change from the liquid state being particularly unknown. Presently, there is insufficient data in the literature regarding multiphase CO2 to adequately design a multiphase-tolerant turbine, so generation of foundational data is required. This experimental study investigates the flow characteristics of sub-sonic liquid CO2 undergoing expansion and phase change in a converging-diverging nozzle. The nozzle is instrumented to measure static pressure, unsteady pressure, temperature, and density. The static pressure transducers are located at 27 axial locations to accurately characterize the pressure profile in the nozzle. High-accuracy RTDs are located at the entrance and exit of the nozzle, and three dynamic pressure transducers are strategically located to capture any unsteady phenomena. During testing, values of mass flow and nozzle inlet pressure are swept to vary the pressure drop and fluid properties. The measured total pressure drop in the nozzle is compared to a homogenous model and the Lockhart-Martinelli correlation method, with the latter predicting loss quite closely. The resulting data set is valuable for validating multiphase numerical models in a simple geometry before implementation of these models in turbomachinery design.

25 ENERGY STORAGE↗

DOE OSTI2022

Thermal-Mechanical Analysis of an Additive Manufacturing Ceramic Heat Exchanger for High-Temperature Recuperator in a sCO2 Power System

Supercritical CO2 (sCO2) Brayton power cycle can be configured in a closed-loop power system and has a potentially high cycle efficiency. Compactness and high efficiency of a sCO2 power block make the sCO2 Brayton cycle a versatile power cycle in broad applications. While many heat sources are of sufficient intensity to produce high temperature working fluids to achieve high cycle efficiency, the thermal-mechanical stability of traditional materials (e.g., steels and nickel-based superalloys) used in construction of heat exchangers and turbine components limits the operating conditions and thus thermodynamic efficiency of the system. This effort seeks to establish the viability of ceramic heat exchanger technologies for the most extreme operating conditions envisioned for power generation and other high temperature processes. Heat exchangers constructed from ultra-high temperature ceramics, a class of extreme environment materials featuring melting points (Tmp.) above 3000 degrees C, is particularly appealing for sCO2 Brayton cycles given their ultra-low creep rates and very high retained strength at low homologous temperatures (i.e., T < 0.5 Tmp., or at least 1500 degrees C). To translate these materials properties to ultra-high temperature heat exchangers, innovations are required in ceramic manufacturing techniques to realize the complex architectures featured in compact heat exchangers with high power density. With appropriate processing, ZrB2-SiC based compositions can be sintered to near full density and shaped into complex topologies via ceramic additive manufacturing methods. This paper analyzes heat exchanger designs and explores thermal-mechanical implications of the operating environment. Thermal flow, heat transfer, and conjugate mechanical analyses provide insights into benefits and risks associated with the design approach.

additive manufacturing↗