Particle Flow Testing of a Multistage Falling Particle Receiver Concept: Staggered Angle Iron Receiver (StAIR).
Abstract not provided.
Yue, Lindsey↗
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Thermal-Hydraulic Analysis and Experimental Flow Testing of LEU-UAlx Dispersion Target Plates for Irradiation in the High Flux Isotope Reactor
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Goth, Nolan↗
Lessons Learned with Additive Manufacturing – Transformational Challenge Reactor Flow Test Articles
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See, Nate↗
AN UPDATE ON THE STATUS OF A REDUCED FLOW TEST OF A 10MW 700⁰C SCO2 INTEGRALLY GEARED COMPANDER
In order to maintain viability as a future power-generating technology, concentrating solar power (CSP) must reduce its levelized cost of electricity (LCOE). One component of solving this problem is reducing the cost of the power block while simultaneously increasing the efficiency of the thermodynamic cycle. One disruptive technology that has the promise to accomplish this is supercritical CO2 based power cycles. These cycles are conceptually similar to steam cycles; however, they have substantially smaller turbomachinery at equivalent power while also delivering more efficiency at turbine inlet temperatures of 500-700℃. This paper will summarize the current status of a US Department of Energy project to develop machinery to support a 10 MW sCO2 power cycle. The team of Southwest Research Institute® (SwRI®) and Hanwha Power Systems America, proposed to develop an integrally-geared (IG) compressor-expander (compander) for use in a nominal 10 MW-scale CSP supercritical carbon dioxide (sCO2) plant application. This integrally-geared compander (IGC) comprises multiple pinion shafts interconnected on a single bull gear to create a compact package, and utilizes a low-cost, low-speed driver. In addition, the integrally-geared architecture allows each pinion to operate at different rotational speeds to optimize performance and easily allow for inter-stage cooling and turbine re-heat to further enhance both stage and cycle efficiency. The close integration of all turbomachinery elements into a single integrally-geared (IG) machine creates a design that lends itself to power block modularization, which makes it suitable for waste heat recovery, fossil fuel power plants, and especially CSP applications.
14 SOLAR ENERGY↗
Flow Sensor Test Article (F-STAr) - Water Testing and Commissioning Report for FY2024
Argonne National Laboratory’s Mechanism Engineering Test Loop (METL) facility is developing new experimental testing capabilities with the Flow Sensor Test Article (F-STAr). F-STAr’s mission is to provide high flowrate, sodium submersible testing capabilities to support the development of sodium cooled nuclear fission reactors. Figure 1 shows a model of F-STAr (left) and a photo of the partially assembled test article (right) with several of the main components labeled. The system currently includes a large pump with desired flowrates of up to 100 GPM; an immersion heater with a maximum power of 5 kW; an immersion cooler with an estimated maximum cooling power of 2 kW; and an experimental test section to support sub-test articles. Initially, F-STAr will be setup for testing flow sensors, specifically Eddy Current Flow Sensors (ECFS). However, the system can be reconfigured to support a wide range of testing needs. For example, F-STAr could be setup to complete testing of hydraulic components, heat exchangers, hydrodynamic bearings, seals, and more. This report will provide an update on the development of F-STAr with a focus on the water testing and commissioning activities during Fiscal Year 2024 (FY24). First, the report will focus on describing the pump development. Specifically, updates will be provided on troubleshooting the pump’s excessive vibrational issues. In addition to updates on the pump, pressure-flowrate performance testing in water will be described. Furthermore, updates will be provided on a pump shaft bushing development as well as rigging procedures. Future work and paths forward for F-STAr will be described. Finally, a short summary on the ECFS development will be described at the end of the report.
22 GENERAL STUDIES OF NUCLEAR REACTORS↗
Flow Sensor Test Article (F-STAr) - Assembly and Water Testing Report
The Flow Sensor Test Article (F-STAr) is a new test article under development for the Mechanisms Engineering Test Loop (METL) facility at Argonne National Laboratory. F-STAr’s purpose is to provide sodium submersible, high flowrate testing capabilities for the development of sensors, components, fluid studies and more. This report will provide a status update on the assembly and initial qualification testing of F-STAr. All components have been manufactured and received. Some modifications to these components were made to support minor changes in the test article design. Additionally, the power distribution, and data acquisition and control enclosures were designed, completed, and tested along with the control system software. Furthermore, initial qualification testing was completed in water. Finally, the F-STAr submersible Electromagnetic Flowmeter (EMFM) was completed and calibrated in flowing sodium.
42 ENGINEERING↗
CFD Simulation of Helium Flow Loop Test Section
A helium flow loop is being assembled at Oak Ridge National Laboratory to analyze heat transfer enhancement for systems such as blanket and divertor components. To efficiently identify optimum geometries for heat transfer enhancement in these applications, simulation work is performed to optimize test section designs that are built and tested in the helium flow loop that operates at 4 MPa and a mass flow rate of 100 g/s. Different ribbed geometries that examine rib shape, rib height, rib orientation, rib spacing, and three dimensional orientation are modeled and simulated in STAR-CCM+ to compare their ability to remove heat and mitigate pressure drop. Following the simulations, models are selected and manufactured for the helium flow loop tests. Simulations initially focus on a hydrodynamic study to determine the appropriate mesh and physics models and then add a heat flux to analyze the heat transfer abilities of the models. The simulations are run in steady state and use a Reynolds-averaged Navier-Stokes k-ε turbulence model. The helium is modeled as an ideal gas. The simulation explores models of geometries that enhance the heat transfer and decrease pressure drop with an overall goal of increasing fluid collision with the wall. Enhanced geometries are simulated to select appropriate designs for manufacturing, and preliminary experimental results are used to validate the simulations. Furthermore, the factors that are being analyzed in the comparison between the experimental and the simulated results include matching thermocouple temperatures, pressure drop, roughness, and fluid velocity.
42 ENGINEERING↗
Flow Sensor Test Article (F-STAr) (Design and Fabrication Status Report)
The Flow Sensor Test Article (F-STAr) is a test article currently under construction for the Mechanisms Engineering Test Loop (METL). F-STAr was designed to provide high sodium flowrate capabilities for sensor calibration, component testing, and fluid studies. Figure 1 shows two solid model views of the new test article. F-STAr includes a high-capacity pump that can provide a nominal flowrate of 120 GPM; a test section support structure that can accommodate a wide array of sub-test articles and their instrumentation; and finally, a heating and cooling system to aid in controlling the testing environment. Initially, F-STAr will be configured to test liquid metal flow sensors, specifically field shift sensors like the Eddy Current Flow Sensors (ECFS) based on the RDT C4-7T standard. To test these sensors, two test sections were designed that attempt to model Sodium Fast Reactor (SFR) outlet conditions. Figure 2 shows models of the “Full-Scaled Test Section” (FSTS) that represents a generic SFR fuel handling socket and a “Pseudo-Scaled Test Section” (PSTS) that represents a generic array of scaled fuel handling sockets. While F-STAr will be configured to test ECFS’s, it can also be outfitted to meet other experimental needs. For example, F-STAr could be setup with a test section that includes a fluidic diode or a component test investigating the performance of hydrodynamic bearings. Other test sections include studies of sodium thermal hydraulics like thermal striping. Overall, F-STAr is a flexible test article designed to accommodate many needs. This report will provide a status update on the design and construction of F-STAr. Manufacturing of all components has commenced, and several components have already been completed. These components include the pump and test section assembly stand. Other components, such as the heater, have been completed but were rejected due to the vendor not meeting the requirements of the purchase order. Lastly, the submersible flowmeter and main flange components are under construction, and their status will be reviewed in this report. Overall, most of the F-STAr components and parts will be completed by the end of September 2022.
42 ENGINEERING↗
Lost Circulation Materials in Geothermal Drilling: Thermal Degradation, Viscosity, Compression, and Flow Loop Tests
This dataset provides a set of experimental data on the performance of lost circulation materials (LCMs) used in geothermal drilling operations. It includes results from four distinct tests: thermal degradation, viscosity measurements, compression tests, and high-temperature flow loop experiments. The materials tested, such as cedar fiber, cotton seed hulls, magma fiber, microcellulose, and sawdust, were analyzed under a range of conditions to assess their effectiveness in mitigating fluid losses in geothermal wells. Data on thermal degradation explores mass loss, water loss, and gas release for each material when subjected to temperatures between 90C and 250C. Viscosity measurements capture the behavior of LCM mixtures under different temperatures, while compression tests investigate the structural integrity of both undegraded and thermally degraded materials. The high-temperature flow loop experiments simulate geothermal well conditions, analyzing how different materials and mixtures affect fluid flow and sealing performance in a fractured reservoir environment. In addition to the experimental data, the dataset includes photos documenting the materials, schematics of test setups, and several published manuscripts that provide detailed insights into the experimental methods and findings.
15 GEOTHERMAL ENERGY↗
The EGS Collab Project – Stimulations at Two Depths
The EGS Collab project, supported by the US Department of Energy, is performing intensively monitored rock stimulation and flow tests at the 10-m scale in an underground research laboratory to address challenges in implementing enhanced geothermal systems (EGS). Data and observations from the field tests are compared to simulations to understand processes and build confidence in numerical modeling of the processes. We have completed Experiment 1 (of 3), which examined hydraulic fracturing in a well-characterized underground fractured phyllite test bed at a depth of approximately 1.5 km at the Sanford Underground Research Facility (SURF) in Lead, South Dakota. Testbed characterization included fracture mapping, borehole acoustic and optical televiewers, full waveform sonic, conductivity, resistivity, temperature, campaign p- and s-wave investigations and electrical resistance tomography. Borehole geophysical techniques including passive seismic, continuous active source seismic monitoring, electrical resistance tomography, fiber-based distributed strain, distributed temperature, and distributed acoustic monitoring, were used to carefully monitor stimulation events and flow tests. More than a dozen stimulations and nearly one year of flow tests were performed. Quality data and detailed observations were collected and analyzed during stimulation and water flow tests using ambient temperature and chilled water. We achieved adaptive control of the tests using real-time monitoring and rapid dissemination of data and near-real-time simulation. More detailed numerical simulation was performed to answer key experimental design questions, forecast fracture propagation trajectories and extents, and analyze and evaluate results. Data are freely available from the Geothermal Data Repository. Experiment 2 examines the potential for hydraulic shearing in amphibolite at a depth of about 1.25 km at SURF. This site has a different set of stress and fracture conditions than Experiment 1. The Experiment 2 testbed consists of nine subhorizontal boreholes configured in two fans of two boreholes which surround the testbed and contain grouted-in electrical resistance tomography, seismic sensors, active seismic sources and distributed fiber sensors. A “five-spot” set of test wells that extends from a custom mined alcove includes an injection well and four production/monitoring wells. The testbed was characterized geophysically and hydrologically, and three stimulations have been performed using the Step-Rate Injection Method for Fracture In-Situ Properties (SIMFIP) tool to measure strains, and a new strain quantifying tool (downhole robotic strain analysis tool -DORSA) was deployed in a monitoring hole during stimulation. Real-time data were broadcast during stimulations to allow real-time response to arising issues.
EGS Collab, Enhanced Geothermal Systems, EGS, fiel↗
The EGS Collab Project: Status and Accomplishments
The EGS Collab project, supported by the US Department of Energy, is addressing challenges in implementing enhanced geothermal systems (EGS). This includes improving understanding of the stimulation of crystalline rock to create appropriate flow pathways, and the ability to effectively simulate both the stimulation and the flow and transport processes in the resulting fracture network. The project is performing intensively monitored rock stimulation and flow tests at the 10-m scale in an underground research laboratory. Data and observations from the field test are compared to simulations to understand processes and to build confidence in numerical modeling of the processes. In Experiment 1, we examined hydraulic fracturing an underground test bed at the Sanford Underground Research Facility (SURF) in Lead, South Dakota, at a depth of approximately 1.5 km. We drilled eight sub-horizontal boreholes in a well-characterized phyllite. Six of the boreholes were instrumented with many sensor types to allow careful monitoring of stimulation events and flow tests, and the other two boreholes were used for water injection and production. We performed a number of stimulations and flow tests in the testbed. Our monitoring systems allowed detailed observations and collection of numerous data sets of processes occurring during stimulation and during dynamic flow tests. Long-term ambient temperature and chilled water flow tests were performed in addition to many tracer tests to examine system behavior. Data were rapidly analyzed, allowing adaptive control of the tests. Numerical simulation was used to answer key experimental design questions, to forecast fracture propagation trajectories and extents, and to analyze and evaluate results. Many simulations were performed in near-real-time in conjunction with the field experiments, with more detailed process study simulations performed on a longer timeframe. Experiment 2 will examine hydraulic shearing in a test bed being built at the SURF at a depth of about 1.25 km in amphibolite under a different set of stress and fracture conditions than Experiment 1. Five sets of fracture orientations were considered in design, and three orientations seem to be consistently observed.
EGS Collab↗
The EGS Collab project: Outcomes and lessons learned from hydraulic fracture stimulations in crystalline rock at 1.25 and 1.5 km depth
With the goal of better understanding stimulation in crystalline rock for improving enhanced geothermal systems (EGS), the EGS Collab Project performed a series of stimulations and flow tests at 1.25 and 1.5 km depths. The tests were performed in two well-instrumented testbeds in the Sanford Underground Research Facility in Lead, South Dakota, United States. The testbed for Experiment 1 at 1.5 km depth contained two open wells for injection and production and six instrumented monitoring wells surrounding the targeted stimulation zone. Four multi-step stimulation tests targeting hydraulic fracturing and nearly year-long ambient temperature and chilled water flow tests were performed in Experiment 1. The testbed for Experiments 2 and 3 was at 1.25 km depth and contained five open wells in an outwardly fanning five-spot pattern and two fans of well-instrumented monitoring wells surrounding the targeted stimulation zone. Experiment 2 targeted shear stimulation, and Experiment 3 targeted low-flow, high-flow, and oscillating pressure stimulation strategies. Hydraulic fracturing was successful in Experiments 1 and 3 in generating a connected system wherein injected water could be collected. However, the resulting flow was distributed dynamically, and not entirely collected at the anticipated production well. Thermal breakthrough was not observed in the production well, but that could have been masked by the Joule-Thomson effect. Shear stimulation in Experiment 2 did not occur - despite attempting to pressurize the fractures most likely to shear - because of the inability to inject water into a mostly-healed fracture, and the low shear-to-normal stress ratio. The EGS Collab experiments are described to provide a background for lessons learned on topics including induced seismicity, the correlation between seismicity and permeability, distributed and dynamic flow systems, thermoelastic and pressure effects, shear stimulation, local geology, thermal breakthrough, monitoring stimulation, grouting boreholes, modeling, and system management.
15 - GEOTHERMAL ENERGY↗
Evolution of Microstructure and Surface Characteristics of FeCrAl alloys when Subjected to Flow Boiling Testing
FeCrAl alloys are candidate materials for manufacturing accident-tolerant fuel (ATF) cladding intended for light water reactors to increase fuel reliability and safety during design-basis and beyond-design-basis accident scenarios. The evolution of the materials' surface characteristics, microstructure, and mechanical properties when exposed to the Critical Heat Flux (CHF) in flow boiling testing is crucial for safety analysis while providing insights into their thermal-hydraulic performance in nuclear reactors. After CHF, the surface chemistry of two FeCrAl alloys, APMT and C26M, was studied to understand their evolution at the early stage of high-temperature excursions in short time periods. The results indicated a thin layer composed of oxides and hydroxides of Al, Cr, and Fe with varying proportions at different depths in the layer, as indicated by X-ray photoelectron spectroscopy (XPS) and depth profiling. The cross-sections prepared by focused ion beam (FIB) revealed the growth of an oxide layer, in the range of 90-180 nm thick, on the alloys' surfaces. The evolution of the materials' surface chemistry also led to a noticeable post CHF excursion increase in their wettability, with a slight increase in roughness. Further, the investigation of the materials' mechanical properties indicated a modest increase in hardness by 10-15% as well as an increase in their yield strength, as evidenced by the microindentation and ring compression tests conducted before and after CHF testing. Scanning electron Microscopy (SEM) and X-ray diffraction (XRD) were used to investigate microstructural features of the materials and their changes after CHF treatment.
36 MATERIALS SCIENCE↗
TEAMER: DAISY Flow-noise Testing (Abstract)
Evaluating impacts of marine energy devices is generally difficult given the dynamic environment where these devices need to be placed. The University of Washington’s (UW) DAISY (The Drifting Acoustic Instrumentation SYstem) is designed to measure radiated noise around marine energy converters operating in energetic waves and currents. In currents, a primary limitation for measurement fidelity at low frequencies (< 100 Hz) is the potential for non-propagating “flow-noise” to mask propagating sound and inflate estimates of the radiated noise from marine energy converters at frequencies that overlap with hearing sensitivities of fish and some marine mammals. While free-drifting measurements help to minimize the relative velocity that produces flow-noise, significant levels were still observed during initial DAISY tests. This motivated the development of a fabric “flow shield” around the hydrophone that disrupts both flow-noise generation mechanisms proposed by the initial tests. First, the flow shield is a source of substantial drag which keeps the hydrophone package moving with the approximate velocity of the surrounding water, compensating for differential wind or current forcing on the surface expression. By minimizing relative velocity around the hydrophone, turbulence shed by the hydrophone is also minimized. Second, the flow shield creates a largely quiescent pocket around the hydrophone, minimizing advection of free stream turbulence over the hydrophone element. Field data collected in these experiments will test effectiveness of these flow shields and provide quantitative data use and deployment.
16 TIDAL AND WAVE POWER↗
Robust foil regenerator flow loss and heat transfer tests under oscillating flow condition
A regenerator works as an energy storage component in a Stirling engine. Thus, it is one of the most critical components that makes the Stirling engine highly efficient. Traditionally, the regenerators are made of wire media such as woven screens and random fibers. These wire regenerators experience considerably high flow losses through the regenerator due to the flow separation and the resulting vortices. The high flow losses associated with the flow separation and vortices result in a lower engine efficiency. This research is to test a new robust foil regenerator to investigate its feasibility for free-piston Stirling engine applications. The robust foil regenerator is configured with parallel flow channels and stiffening ribs. Comparing to complex flows patterns in woven screen and random fiber regenerators, the flows in the parallel plates are simple and the flow losses are considerably small, and the heat transfer coefficient is also relatively small. To test the regenerator experimentally, a regenerator test rig was manufactured. To verify the accuracy of the test rig, a woven screen regenerator was made and tested prior to the robust foil regenerator test. The friction factor correlation of the woven screen regenerator shows a good agreement with the published regenerator correlations. The robust foil regenerator tests were conducted under the oscillating flow condition with different Reynolds numbers. The flow losses were measured with dynamic pressure transducers and the friction coefficient was derived from measured pressure drop. The measured temperature difference over the regenerator was used to calculate the heat transfer coefficient and Nusselt number. The figure of merit with two methods of NPH/NTU ratio and j/f ratio was calculated to evaluate the suitability of the robust foil regenerator. The results show that the robust foil regenerator has considerably higher figure of merit and therefore, better performance than other types of regenerator.
42 ENGINEERING↗
A high-pressure flow through test vessel for neutron imaging and neutron diffraction-based strain measurement of geological materials
Neutron scattering and neutron imaging have emerged as powerful methods for experimentally investigating material deformation and fluid flow in the interior of otherwise inaccessible or opaque structures. This paper describes the design and provides example uses of a pressure cell developed for investigating such behaviors within geological materials. The cell can accommodate cylindrical samples with diameters up to 38.1 mm and lengths up to 154 mm. Additionally, ports in the cell and a pressure isolating sleeve around the sample allow the independent application of confining pressure up to 69 MPa and axial pressure up to 34.5 MPa. Furthermore, two material versions of the cell have been manufactured and used to date. An aluminum version is typically used for temperatures below 40 °C, because of its relative transparency to neutrons, while a titanium version, which is comparatively more neutron attenuating, is used for experiments requiring triaxial pressurization under conditions up to 350 °C. The pressure cells were commissioned at the VULCAN engineering diffractometer at the Oak Ridge National Laboratory (ORNL), Spallation Neutron Source, and have since been used at the ORNL high flux isotope reactor CG1-D imaging beamline, National Institute of Standard and Technology (NIST) BT-2, and NIST NG6 imaging beamlines.
47 OTHER INSTRUMENTATION↗
Feasibility of carbon foam-based sorbents for the abatement of gaseous mercury and iodine
The U.S. Department of Energy Hanford Site in Washington State is in the process of commissioning the Waste Treatment and Immobilization Plant to process a portion of the 54 million gallons of radioactive and chemical waste from cold war weapon production. Technologies for the capture of volatile species of concern are still being assessed, and new methods and materials are developed as operational and flowsheet mission risks are identified. One such area still being assessed is the abatement efficacy of the Carbon Adsorber units to retain gaseous mercury and 129 I released during processing. It is challenging to predict the mercury chemistry due to the variability of the feed, and different methods/materials are required for the capture of gaseous Hg 0 and Hg II compounds. In this study, the feasibility of using developmental carbon foam (CF) sorbents for the capture of iodine and mercury was assessed using static and dynamic flow testing and compared against a commercially available sorbent, BATII-37. Both CF and CF functionalized with bismuth particles (CF-Bi) chemisorbed iodine, and CF-Bi had similar mercury capture performance to BATII-37 in dynamic flow tests. While species loading concentrations were measurable, limitations in achieving a mass balance prevented a full evaluation of capture efficacy. Nonetheless, the results serve as an important first step in demonstrating the potential for simultaneous iodine and mercury capture.
Hanford site↗
Hydraulic Response to Thermal Stimulation Efforts at Raft River Based on Stepped Rate Injection Testing
The injection well stimulation project at the Raft River geothermal field tests the effect of long-term cold water injection and high pressure injection on well injectivity, improvements to which could reduce operating costs. The primary data for analysis and interpretation of the injection test are step-rate flow tests run before each new phase of the injection. These tests were analyzed using a combination of standard pump-test analytical solution methods and methods developed expressly for the observed conditions. The stepped rate injection tests, combined with long-term flow and pressure response data suggest that the well is located within a fractured formation of low transmissivity but high storativity. These calculated parameters appeared to increase with pressure during the first injection test and the higher values were reproduced during the second stepped rate test. Calculated transmissivity and storativity are on the order of 4E-5 m cm 2 and 1E-4 m Pa -1 , respectively. The apparent pressure dependence of fitted hydraulic parameters may reflect near-well fracture compliance that increased the effective radius of the wellbore during the first test. While the type curve fit analysis also suggests that the reservoir behaves as a uniformly fractured reservoir with a radial flow regime, the hydraulic parameters indicate that condition may exist only a very limited distance (<10 m) from the well. Longer-term pressure response suggests that flow in the system effectively reaches steady state in a period of less than a day, which may reflect pressure stabilization resulting from pressure-dependent permeability or a region of much higher permeability located with a few meters of the well. The transmissivity estimates obtained from this analysis, converted to approximate fracture density and aperture, provide useful constraints on the distance to which the thermal front may migrate from the well during the cold water injection phase of the stimulation project. We estimate that the cooling front will migrate less than a tenth of a kilometer over an approximately one-year injection period. Here, the effects of that cooling, however, may be substantial, because increases in permeability have maximum effect nearest the well.
cold water injection↗