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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 235 records · Page 13
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

An engineering prototype of a late stage ionization cooling cell for a muon collider

Achieving the low emittances necessary for a muon collider requires ionization cooling. Much of that cooling occurs in compact cooling cells where superconducting coils and conventional RF cavities are closely interleaved [1]. The real challenges for these cooling cells reside in their engineering challenges: high field solenoids, RF cavities, and absorbers, often designed near technological limits, placed in close proximity to each other. We thus propose to build a prototype ionization cooling cell to demonstrate the capability of constructing an ionization cooling channel reaching the lowest emittances and to provide engineering input for the design of such beamlines. The magnets and cavities will be powered at their design values, and an absorber will be included along with a mechanism for heating the absorber similarly to how a beam would.

43 PARTICLE ACCELERATORS↗
DOE OSTI2020

Design and Analysis of a Double Wall, Water Cooled Window for Accelerator Based Mo-99 Production

The electron accelerator based Mo-99 production technique requires the use of Rhodotrons to generate 38 MeV, 6.32 mA pulsed electron beams. The introduction of the pulsed beam structure has introduced fatigue concerns in the vacuum-helium windows that did not exist previously for electron beam production via linear accelerators. Previous analysis has shown that temperature fluctuations of approximately 100°C above and below the steady state operating temperature of ~500°C will occur within the windows. A water cooled window will eliminate this concern by reducing the primary mechanical stress due to the 300-psig helium pressure load as well as the secondary thermally induced stress. Although a water cooled window was considered years ago, the complexities of adding an additional water line was unattractive until now. A double wall, water cooled window has been designed and analyzed for this reason. The water cooled window design is shown to decrease the helium-side window temperature to as low as 125°C, while the vacuum-side window is maintained at 161°C at a water flow rate of 3.2 GPM. These low steady state temperatures reduce the thermal stress of the helium-side window significantly. Also, the primary mechanical stress has been reduced by roughly 50% due to the reduced pressure gradient across the helium-side window (150-psig water and 300-psig helium). Considering a Mo-99 production loss of roughly 1%, the water cooled window is a drastic improvement over the previous helium cooled designs and should be greatly considered for future upgrades and redesign.

43 PARTICLE ACCELERATORS↗
DOE OSTI2021

Film Cooling Performance Predictions For Air And Supercritical CO 2

The current study explores the possibility of cooling the vanes and blades of a direct-fired sCO 2 turbine using film cooling geometries. The operating conditions of a direct-fired sCO 2 cycle and thermophysical properties of the fluid at those conditions can alter the flow field characteristics of the coolant jet and its mixing with the mainstream. Very little information is present in the literature regarding the performance of film cooling geometries employing a supercritical fluid. The objective of this study is to estimate the resulting film cooling effectiveness while also capturing the effects of the crossflow-to-mainstream velocity ratio on the coolant jet. A computational fluid dynamic model is used to study the coolant jet exiting a cylindrical hole located on a flat plate, with the coolant fed by an internal channel. Steady-state RANS equations were solved along with the SST kω model to provide the turbulence closure. The operating conditions for the direct-fired sCO 2 turbine are obtained using an in-house Cooled Turbine Model. Numerical predictions revealed that the crossflow effects and jet lift-off were more pronounced in the case of sCO 2 when compared to air. Spatial distribution of flow field and cooling effectiveness will be presented at different operating conditions. Recommendations for future studies will be given wherever applicable.

42 ENGINEERING↗
DOE OSTI2022

Wastewater Recycling Using a Hygroscopic Cooling System

This project by the Energy & Environmental Research Center (EERC), Baltimore Aircoil Company (BAC), and Great River Energy (GRE) evaluated the concept of recycling wastewater at a coal-fired power plant using a hygroscopic cooling system, which is an evaporative cooling technology analogous to conventional cooling towers, except that sparingly soluble dissolved solids are precipitated and removed as waste solids instead of purging them with a liquid blowdown stream. This technology can maximize the use of plant makeup water by obtaining useful evaporative cooling from wastewater while minimizing the volume of wastes needing disposal. Experimental activities were conducted in two phases, a laboratory-based evaluation of the properties of wastewater from the host site, GRE’s Coal Creek Station near Underwood, North Dakota, and a field test of a small pilot hygroscopic cooling system at the host site power plant. Findings from the laboratory study informed the design of the pilot system and the system’s field test performance served as the basis for a techno-economic analysis (TEA) of the hygroscopic recycling concept. At the preferred operating conditions identified during the TEA, the wet-bulb approach temperature of the tower was 7.3°C (13°F) and the volume of blowdown produced by the plant was reduced to 5.4% of its incoming volume. Waste solids produced during field testing were classified as nonhazardous waste based on the measured hazardous element content and evaluation of their leaching potential. However, to qualify as a solid for landfill disposal i.e., as determined by the U.S. Environmental Protection Agency’s paint filter test, it appears that a dewatering step beyond hydrocyclone separation is needed. The baseline levelized cost of wastewater disposal (LCWD) for hygroscopic wastewater recycling was estimated to be $\$ $3.69–$\$ $3.72 per m3 of plant blowdown. Capital cost was estimated to contribute over 54% to the LCWD, and parameters that impact capital cost such as the heat exchange coil material of construction and the tower’s wet-bulb approach temperature were identified as having the greatest impact on overall LCWD. A LCWD estimate prepared for the same application but using thermomechanical brine evaporation was almost 40% higher than that calculated for hygroscopic cooling, despite recovering distilled-quality water for reuse, while the LCWD for disposal-only, deep well injection was estimated to be 30% lower compared to hygroscopic wastewater recycling.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

Modeling the cooldown of cryocooler conduction-cooled devices

Cryocooler conduction cooled devices can experience significant cooldown time due to lower available cooling capacity compares to convection cooled devices. Therefore, the cooldown time is an important design parameter for conduction cooled devices. This article introduces a framework developed in Python for calculating the cooldown profiles and cooldown time of cryocooler conduction-cooled devices such as superconducting magnets and accelerator cavities. The cooldown time estimation problem is essentially a system of ordinary first-order differential equations comprising the material properties (temperature dependent thermal conductivity and specific heat capacity) of the components intertwined with the prevailing heat transfer channels (conduction, radiation, and heat flow across pressed contacts) and the cryocooler capacity. The formulation of this ODE system is first presented. This ODE system is then solved using the in-built Python library odeint. A case study is presented comprising a small cryocooler conduction-cooled copper stabilized niobium-titanium magnet. The case study is supplemented with the Python script enabling the reader to simply tweak the device design parameters and optimize the design from the point of view of slow/fast cooldown.

43 PARTICLE ACCELERATORS↗
DOE OSTI2021

Demonstration of Electron Cooling using a Pulsed Beam from an Electrostatic Electron Cooler

Electron cooling continues to be an invaluable technique to reduce and maintain the emittance in hadron storage rings in cases where stochastic cooling is inefficient and radiative cooling is negligible. Extending the energy range of electron coolers beyond what is feasible with the conventional, electrostatic approach necessitates the use of RF fields for acceleration and, thus, a bunched electron beam. To experimentally investigate how the relative time structure of the two beams affects the cooling properties, we have set up a pulsed-beam cooling device by adding a synchronized pulsing circuit to the conventional electron source of the CSRm cooler at Institute of Modern Physics *. We show the effect of the electron bunch length and longitudinal ion focusing strength on the temporal evolution of the longitudinal and transverse ion beam profile and demonstrate the detrimental effect of timing jitter as predicted by theory and simulations. Compared to actual RF-based coolers, the simplicity and flexibility of our setup will facilitate further investigations of specific aspects of bunched cooling such as synchro-betatron coupling and phase dithering.

Bruker, M. W.↗
DOE OSTI2022

Availability and redundancy design considerations for Electron-Ion Collider cooling water systems and components

The Electron-Ion Collider (EIC) is composed of several large-scale systems, which all require highly available cooling systems based on the Conceptual Design Report. Since the overall EIC availability goal is 85%, all the subsystems will contribute. Availability is defined by the time that a component or system is functional given a required or scheduled run time. The focus of the project was to determine if redundant or extra cooling water and deionized water pumps were needed in a subsystem to increase the overall EIC availability. The largest subsystem in the ring is the 10 o’clock cooling system, so this was used for redundancy analysis. Relationships between the components were defined as parallel, series, or m-out-of-n for the cooling towers, valves, pumps and heat exchangers to perform calculations. A comparison between an original system versus a redundant one was then done using component availability from industry standards. Cost analysis was also performed to see how much the availability and cost would decrease if the redundancy application was not chosen. The Collider-Accelerator Department (CAD) also has a calculation in place for the Relativistic-Heavy Ion Collider (RHIC), so cooling water failure data was collected from their operational log and analyzed for real-life component availability. A comparison of component availability from the CAD data to the industry standards was made through the 10 o’clock cooling system layout. The results showed that the subsystems need to have over a 98% availability for an 85% goal, and that the CAD data is very close to the industry component standards. The cost differential is miniscule compared to the potential availability increase. Therefore, redundant systems can increase the overall EIC availability by a sizable amount and are worth implementing.

43 PARTICLE ACCELERATORS↗
DOE OSTI2021

Fluid dynamic simulation and analysis of water-cooling systems for the Electron-Ion Collider

The Electron-Ion Collider is the newest large-scale project at Brookhaven National Laboratory. The collider’s purpose is to provide further advancements in the knowledge of the universe’s origin by accelerating particles near the speed of light. Our project for this 3.8 km ring was to create a thermal hydraulic steady-state simulation design of the water-cooling system to be cost-effective and energy efficient, as envisioned by Charlie Foltz, the EIC Infrastructure Division Director. The system would include a supply and return header, which cools several thousand components of the ring. The water would then be returned and cooled down using a system of cooling towers and plate and frame heat exchangers. Due to the size of the system and the complexity of the network analysis, a fluid dynamic simulation software, AFT Fathom, was used. Since previous methods of maintaining systems relied on building upon smaller real-life models and implementing empirical data, this flow model was unique and first of a kind in the domain of accelerator design, construction and operation. Therefore, our hydraulic team piloted a new method to perform network analysis on a large scale cooling system. We successfully created several test scenarios for system behavior in a shorter time compared to the method of performing hand calculations. Cooling specifications for heat rejection, pressure drop, flow rate, and pipe sizing were changed based on the individual systems of the vacuum, radio frequency (RF), magnet and power supply, and cryogenics sections. Finally, we used DOE guidelines to perform life-cycle cost analysis with net present value and carbon saving analysis on the systems where pipe size could be optimized.

43 PARTICLE ACCELERATORS↗
DOE OSTI2021

Deployment of the Finite Volume Method in Pronghorn for Gas and Salt cooled Pebble Bed Reactors

This report summarizes the activities related to ”Complete FHR and HTGR pebble bed simulator, including initial validation” funded by the NEAMS thermal-hydraulics focus area. The activity revolves around the coarse-mesh thermal-hydraulics code Pronghorn and its application to gas and salt cooled Pebble bed reactor (PBR). The main difference between gas and salt cooled PBR from a thermal-hydraulics perspective is the fluid. To address the difference in fluid behavior, two separate approaches are implemented in the MOOSE Navier Stokes module: 1) a Boussinesq approximation and 2) a fully compressible formulation. The developed finite volume method capabilities are used for improving pre-existing gas-cooled and salt-cooled pebble-bed reactor models. A steady-state, multiphysics gas-cooled pebble-bed reactor model is created that couples the equilibrium core depletion capability developed in previous work, and the finite volume method capability developed for this report. The salt-cooled pebble-bed reactor model is upgraded to use the incompressible finite volume method capability and then extended to three spatial dimensions. Finally, several verification-and-validation exercises performed with Pronghorn are documented using the verification-and-validation report of the MooseDoc system. The goal of this effort to document the verification-and-validation level of Pronghorn and improve stakeholder confidence in the results obtained with Pronghorn.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2023

Development of a Prototype Superconducting Radio-Frequency Cavity for Conduction-Cooled Accelerators

Recent progress in the development of high-quality Nb?Sn film coatings along with the availability of cryocoolers with high cooling capacity at 4 K makes it feasible to operate SRF cavities cooled by thermal conduction at relevant accelerating gradients for use in accelerators. We have developed a prototype single-cell cavity to prove the feasibility of operation up to the accelerating gradient required for 1 MeV energy gain, cooled by conduction with cryocoolers. The cavity has a ~3 ¿m thick Nb?Sn film on the inner surface, deposited on a ~4 mm thick bulk Nb substrate and a bulk ~7 mm thick Cu outer shell with three Cu attachment tabs. The cavity was tested up to a peak surface magnetic field of 53 mT in liquid He at 4.3 K. A horizontal test cryostat was designed and built to test the cavity cooled with three cryocoolers. The rf tests of the conduction-cooled cavity achieved a peak surface magnetic field of 50 mT and stable operation was possible with up to 18.5 W of rf heat load. The peak frequency shift due to microphonics was 23 Hz. These results represent the highest peak surface magnetic field achieved in a conduction-cooled SRF cavity to date

Ciovati, Gianluigi↗
DOE OSTI2024

Testing of Helium-Cooled Metal Molybdenum Disk Target

NorthStar Medical Radioisotopes LLC is planning to produce an important medical radioisotope, molybdenum-99 (Mo-99), through photonuclear reaction on molybdenum-100 (Mo-100). In this approach, molybdenum metal will be bombarded with a 40-MeV electron beam. Because enriched Mo-100 is expensive, it is desired to use as much beam power as possible to achieve maximum production yield and minimize target mass. This objective leads to very high beam power density (heat deposition in the target), which sets challenging requirements for cooling. Together with scientists at Los Alamos National Laboratory, a team at Argonne National Laboratory has developed and demonstrated a cooling approach using pressurized helium, which allows for efficient heat removal. One of the main challenges in this approach is the management of the heat load on the target window. The target window separates the high-pressure helium inside the target from the vacuum in the beamline, so it is constantly under stress from differential pressure. Also, the window is cooled only by the helium gas flowing on one side, making the window cooling even more challenging. High heat deposition in the target disks also imposes a strict requirement on performance of the helium cooling system and thickness of the target disks. The target disks are produced from metal powder via a press-and-sinter process. The resulting disks do not possess tensile strength as high as solid molybdenum and might not survive the vibration from the high-velocity helium coolant and high thermal stress from beam heating. An Argonne team of scientists performed a series of tests at Argonne’s Low Energy Accelerator Facility (LEAF) [3-7]. This report describes two series of tests for scale down production target designs that utilize full-scale 29 millimeters diameter, 0.75 mm thick press-and-sintered disks. We performed two thermal tests with different beam parameters and configurations of the disk laminations. We compared the results of the window temperature measurements and cooling system parameters obtained in the experiments with those predicted by analytical calculations and Computation Flow Dynamic (CFD) simulations. Results of the experiments and calculations are presented below.

36 MATERIALS SCIENCE↗
DOE OSTI2024

An Engineering Prototype of a Late Stage Ionization Cooling Cell for a Muon Collider

Achieving the low emittances required for a muon collider requires ionization cooling. Much of that cooling occurs in compact cooling cells where superconducting coils and conventional RF cavities are closely interleaved. The real challenges for these cooling cells reside in their engineering challenges: high field solenoids, RF cavities, and absorbers, often designed near technological limits, placed in close proximity to each other. We thus propose to build a prototype ionization cooling cell to demonstrate the capability of constructing an ionization cooling channel reaching the lowest emittances and to provide engineering input for the design of such beamlines.

43 PARTICLE ACCELERATORS↗
DOE OSTI2025

Tritium Production Estimates in EIC Cooling Water Systems

Annual tritium production in EIC cooling water has been estimated in one sextant cooling system from expected electron beam and proton beam losses in the tunnel. Beam losses and the secondary particles they produce are the only source within the RHIC Tunnel for producing radioactivity in cooling water, including tritium. The need to estimate tritium production supports decisions on whether cooling water systems are required to meet Suffolk County Article 12 requirements (e.g., double-walled piping, leak detection and containment, etc.). Results are extended to the remaining sextant cooling water systems because of the similarity in tunnel cooling water loads and system volumes.

43 PARTICLE ACCELERATORS↗
DOE OSTI2026

Microstructure Validation of Graph Theory Model-Derived Cooling Rates in the Wire Arc Additive Manufacturing of ER70S-6 Steel

Wire arc additive manufacturing (WAAM) enables high-rate fabrication of large metallic components, but spatial variations in thermal history can lead to microstructural heterogeneity that requires efficient process models to evaluate. This study evaluates whether cooling rates extracted from a graph theory model (GTM)-based thermal simulation are consistent with the microstructural evolution observed in an ER70S-6 WAAM wall. Thermal histories from the model were analyzed at selected build heights, and cooling rates were extracted from the final thermal excursion through the austenite phase field. Microstructures at corresponding locations were characterized using electron backscatter diffraction (EBSD) to quantify grain size distributions, and pearlite interlamellar spacing was used as an additional indicator of cooling behavior. The modeled cooling rates were highest near the substrate and generally decreased with build height, consistent with the observed reduction in the fine grain fraction and the progressive shift in the grain size distribution as build height increased. Pearlite spacing trends also supported the modeled cooling rate variation. These results indicate that GTM-derived thermal histories can be post-processed into metallurgically meaningful cooling rate estimates for WAAM steel builds and linked to dataset specific empirical grain size distribution relationships for process–thermal history–microstructure assessment.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Inverse Compton Cooling in the Coronae of Simulated Black Hole Accretion Flows

Here we present a formulation for a local cooling function to be employed in the diffuse, hot corona region of 3D GRMHD simulations of accreting black holes. This new cooling function calculates the cooling rate due to inverse Compton scattering by considering the relevant microphysics in each cell in the corona and approximating the radiation energy density and Compton temperature thereby integrating over the thermal seed photon flux from the disk surface. The method either assumes the ion and electron temperatures are equal (1T) or calculates them separately (2T) using an instantaneous equilibrium approach predicated on the actual relevant rate equations (Coulomb and Compton). The method is shown to be consistent with a more detailed ray-tracing calculation where the bulk of the cooling occurs, but is substantially less costly to perform. As an example, we apply these methods to a harm3d simulation of a 10M⊙, non-spinning black hole, accreting at nominally 1% the Eddington value. This new approach leads to radiative efficiency values sime65% above Novikov–Thorne, with a larger fraction of total cooling in the corona as compared to simulations performed using the original target-temperature cooling function. Time-averaged post-processing reveals that the continuum spectral observations predicted from these simulations are qualitatively similar to actual X-ray binary data, especially so for the 1T approach, which yields a harder power-law component (Γ = 2.25) compared to the 2T version (Γ = 2.53).

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2023

High-energy Radiation and Ion Acceleration in Three-dimensional Relativistic Magnetic Reconnection with Strong Synchrotron Cooling

Abstract We present the results of 3D particle-in-cell simulations that explore relativistic magnetic reconnection in pair plasma with strong synchrotron cooling and a small mass fraction of nonradiating ions. Our results demonstrate that the structure of the current sheet is highly sensitive to the dynamic efficiency of radiative cooling. Specifically, stronger cooling leads to more significant compression of the plasma and magnetic field within the plasmoids. We demonstrate that ions can be efficiently accelerated to energies exceeding the plasma magnetization parameter, ≫ σ , and form a hard power-law energy distribution, f i ∝ γ −1 . This conclusion implies a highly efficient proton acceleration in the magnetospheres of young pulsars. Conversely, the energies of pairs are limited to either σ in the strong cooling regime or the radiation burnoff limit, γ syn , when cooling is weak. We find that the high-energy radiation from pairs above the synchrotron burnoff limit, ε c ≈ 16 MeV, is only efficiently produced in the strong cooling regime, γ syn < σ . In this regime, we find that the spectral cutoff scales as ε cut ≈ ε c ( σ / γ syn ) and the highest energy photons are beamed along the direction of the upstream magnetic field, consistent with the phenomenological models of gamma-ray emission from young pulsars. Furthermore, our results place constraints on the reconnection-driven models of gamma-ray flares in the Crab Nebula.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2020

Turbine component and methods of making and cooling a turbine component

A turbine component includes a root and an airfoil extending from the root to a tip opposite the root. The airfoil forms a leading edge and a trailing edge portion extending to a trailing edge. A plurality of axial cooling channels in the trailing edge portion of the airfoil are arranged to permit axial flow of a cooling fluid from an interior of the turbine component at the trailing edge portion to an exterior of the turbine component at the trailing edge portion. A method of making a turbine component includes forming an airfoil having a trailing edge portion with axial cooling channels. The axial cooling channels are arranged to permit axial flow of a cooling fluid from an interior to an exterior of the turbine component at the trailing edge portion. A method of cooling a turbine component is also disclosed.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

Energy efficient data center liquid cooling with geothermal enhancement

A data center cooling system is operated in a first mode, has an indoor portion wherein heat is absorbed from components in the data center by a heat transfer fluid, and has an outdoor heat exchanger portion and a geothermal heat exchanger portion. The first mode includes ambient air cooling of the heat transfer fluid in the outdoor heat exchanger portion and/or geothermal cooling of the heat transfer fluid in the geothermal heat exchanger portion. Based on an appropriate metric, a determination is made that a switch should be made from the first mode to a second, different, mode; and, responsive thereto, the data center cooling system is switched to the second mode. The second mode includes at least another of ambient air cooling of the heat transfer fluid in the outdoor heat exchanger portion and geothermal cooling of the heat transfer fluid in the geothermal heat exchanger portion.

15 GEOTHERMAL ENERGY↗