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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 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

System and method of making an enhanced cast iron crankshaft

A method and system for manufacturing a cast iron crankshaft for a vehicle are provided. The system comprises a molding unit arranged to form a negative sand cast mold of the cast iron crankshaft. The mold comprising at least one molded cavity having a pattern with dimensions of the cast iron crankshaft. The system further comprises a feeding mechanism comprising a riser having a connector through which molten metallic material flows to the cast mold. The feeding mechanism feeds the molten metallic material at a riser connection angle in the at least one mold cavity. The riser connection angle corresponds to a connector modulus. The connector modulus is 20% greater than a cast modulus. The riser geometry corresponds to a riser modulus. The riser modulus is 20% greater than the connector modulus. The system further comprises a furnace, a cooling area, a separation unit, a controller and a power source.

Wang, Liang↗
DOE OSTI2020

An Experimental Study of Design and Performance for the Water-Based Reactor Cavity Cooling System

The document summarizes the test activity conducted at the Texas A&M University water-cooled Reactor Cavity Cooling System experimental facility. Flow and temperature characterization of the risers' panel is conducted using advanced measurement techniques. Steady-state and transient scenarios are studied, analyzed, and discussed in the report. The experimental work is complemented with modeling and simulations using system level codes.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2020

Computational Fluid Dynamics Analysis of a 12 MW Circulating Fluidized Bed Rise

A three-dimensional (3D) two fluid model (TFM) model of the 12 MW circulating fluidized bed (CFB) riser at Chalmers University was developed using the open-source Multiphase Flow with Interphase eXchanges (MFiX) Software Suite. The hydrodynamic behavior of the riser was validated by comparing axial pressure profiles from experimental measurements with the results from the simulations. Under some of the operating conditions where there was no external circulation of solids, the pressure profiles from the simulation matched well with the experimental measurements. For the cases where there was external circulation of solids, the pressure profiles with the monodisperse solid phase modeling underpredicted the solids concentration in the freeboard region. With the inclusion of polydispersity in the model, the predicted pressure profiles agreed well with the experimental measurements. A two-dimensional (2D) model of the riser was used to perform simulations of coal combustion. The predicted flue gas outlet compositions of oxygen and carbon dioxide compared reasonably to experiments. The experiments also reported some concentration of carbon monoxide which was overpredicted in the simulations. Additional experimental data such as axial oxygen concentration profile and pressure profiles were also compared with the experiment. It was observed that the oxygen concentration in the bottom bed from the simulations was higher than in the experiments, which suggested that most of the oxidation reactions occurred in the bottom bed. The concentration of volatiles and char in the simulations was lower in the bottom bed than in the experiments, which suggest that there is not sufficient penetration of the solid phase species into the bed.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2022

Controlling a power output of a nuclear reaction without control rods

A nuclear power system includes a reactor vessel that includes a reactor core that includes nuclear fuel assemblies configured to generate a nuclear fission reaction. A representative nuclear power system further includes a riser positioned above the reactor core and a primary coolant flow path that extends from a bottom portion of the reactor vessel, through the reactor core, and through an annulus between the riser and the reactor vessel. A primary coolant circulates through the primary coolant flow path to receive heat from the nuclear fission reaction and release the heat to a power generation system configured to generate electric power. The nuclear power system further includes a control rod assembly system positioned in the reactor vessel and configured to position control rods in only two discrete positions.

Callaway, Allyson↗
DOE OSTI2024

Controlling a power output of a nuclear reactor without using control rods

A nuclear power system includes a reactor vessel that includes a reactor core that includes nuclear fuel assemblies configured to generate a nuclear fission reaction. A representative nuclear power system further includes a riser positioned above there actor core and a primary coolant flow path that extends from a bottom portion of the reactor vessel, through the reactor core, and through an annulus between the riser and the reactor vessel. A primary coolant circulates through the primary coolant flow path to receive heat from the nuclear fission reaction and release the heat to a power generation system configured to generate electric power. The nuclear power system further includes a control rod assembly system positioned in the reactor vessel and configured to position control rods in only two discrete positions.

Callaway, Allyson↗
DOE OSTI2022

Scaling CFB risers: Maintaining microstructure dynamics

Over the years there have been numerous approaches to develop a scaleup methodology for circulating fluidized beds. Many of these past approaches have relied on macroscopic definitions of similitude to define dimensionless groups such as Reynolds number, Froude number, density ratios, and dimensional ratios involving different length scales. These approaches have demonstrated various levels of success, but often fail when used outside the bounds of experimental datasets. The issue with these methods is that they rely on macroscopic similitude with the hopes that those conditions would provide microscopic similitude as it does in single phase systems where the Buckingham Pi techniques have given reasonable success. Two of the main reasons for failure are 1) changing fluidization regimes and 2) changing material properties that result in the material falling into a different Geldart group. Both are certain to change the microstructure (local instantaneous volume solids fraction) and changes to the microstructure affect the interphase transport properties of the reactor system, namely the mass transfer and heat transfer. Here, this work presents a new approach towards scaling based upon maintaining similitude at the microscale. It reviews a novel dimensionless flow regime map developed from analysis of the deterministic chaos parameters and higher order moments to ensure microstructure similitude. The work then examines four cases from the literature to assess the scaling approach used: (1) same particle-different scale risers for Geldart Group B particles, (2) Glicksman scaling of atmospheric circulating fluidized bed combustor, (3) same particle-different scale risers for Geldart Group A particles and (4) Glicksman scaling for pressurized gasification. General findings are that none of the scaling approaches produced directly applicable microstructure similar behavior based upon the chaotic and higher moment analysis. The positive take away is that the approach can define scale conditions that will provide similar microstructure that can be us to predict transport behavior.

42 ENGINEERING↗
DOE OSTI2025

FY-25 Progress on Computational Modeling of the Water Based NSTF

This report summarizes the system level modeling using RELAP5-3D of the Natural Convection Shutdown Heat Removal Test Facility (NSTF) completed in FY25. This year’s work focuses on a new tank configuration where the inlet of the tank was lowered in elevation by 45”. The stability boundaries of the NSTF are thoroughly studied and stability maps are constructed based on the stability and the oscillation patterns of the system. Five distinct operational modes are identified, namely single-phase liquid, uniform double peak oscillations, uniform sinusoidal oscillations, stable two-phase flow, and non-uniform oscillations. Next, the riser inlet throttling case of experimental test Run-104 is simulated with the RELAP5 model where good agreement is obtained between the model and the experimental data. The simulation also highlights the effects of backflow of water from the tank to the upper region of the chimney. Additionally, the decay heat removal test of Run-99 is simulated with the RELAP5 model. Comparison is carried out between this run and a similar run with the mid-tank inlet of Run-74 performed in FY22. With the lower tank inlet, the RELAP5 model is able to predict the experimental data more accurately than the previous mid tank inlet configuration. The discrepancy in model prediction accuracy highlights the non-symmetrical spatial effects in the tank that would otherwise be more easily captured with higher fidelity models. Lastly, two exploratory studies are conducted to investigate the behaviors of the NSTF when 1) heating is provided to the downcomer and 2) a bypass channel is added between the horizontal chimney section to the downcomer.

42 ENGINEERING↗
DOE OSTI2020

Finite Volume Discretization of the Euler Equations in Pronghorn

Modeling flow and heat transfer in high temperature gas reactors (HTGR) requires the ability to model a wide range of flow speeds from slow (natural convection), to intermediate (forced-flow conditions), to supersonic regimes (depressurization) for a wide range of geometries including the pebble bed, upper and lower plenum, and risers. In previous work, Pronghorn has effectively modeled low-to-medium speed flows in scenarios such as the one described in the two-dimensional PBMR-400 benchmark, using its finite-element-based streamline-upwind Petrov-Galerkin (SUPG) stabilized implementation of the Euler equations. However, limitations of this method become apparent when dealing with more complicated geometries (e.g. imposing slip boundary conditions at nodes belonging to two different boundaries) and when gas speeds are fast enough for shocks and supersonic flow to occur. For these problems, the finite-element-based solver lacks robustness and is plagued by slow iterative convergence or even divergence. In order to address these challenges, the Pronghorn code at INL has been updated with new, modified versions of its original equations. The new Pronghorn models are built on the finite volume method with a Harten-Lax-van Leer-Contact (HLLC) Riemann solver based numerical flux method, which (1) allows imposing slip boundary conditions much more robustly and (2) performs well for a wide range of flow speeds. The finite-volume-based flow solver will form the basis for a robust coarse-mesh thermal-hydraulics capability in Pronghorn.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2022

Controlling a power output of a nuclear reaction without control rods

A nuclear power system includes a reactor vessel that includes a reactor core mounted therein. The reactor core includes nuclear fuel assemblies configured to generate a nuclear fission reaction. The reaction vessel does not include any control rod assemblies therein. The nuclear power system further includes a riser positioned above the reactor core, a primary coolant flow path, a primary coolant that circulates through the primary coolant flow path to receive heat from the nuclear fission reaction and release the received heat to generate electric power in a power generation, and a control system communicably coupled to the power generation system and configured to control a power output of the nuclear fission reaction independent of any control rod assemblies.

Callaway, Allyson↗
DOE OSTI2024

Effect of Inlet Throttling on Thermohydraulic Instability in a Large Scale Waterbased RCCS: A System-Level Analysis with RELAP5-3D

This paper presents results from system -level modeling of a water -based reactor cavity cooling system using RELAP5-3D. The computational model is benchmarked with experimental data from a half -scale RCCS test facility at Argonne National Laboratory. The model prediction is first compared with a two-phase oscillatory baseline experimental case where mixed accuracy is obtained. The model shows reasonable prediction of mass flow rate, pressure, and temperature but significant overprediction of void fraction. The model prediction is then compared with a fault case where the inlet of the risers is gradually reduced using a throttling valve. As the valve is closed, the model is able to predict some major flow phenomena observed in the experiment such as the dampening of oscillations, the reintroduction of oscillations, as well as boiling, flashing, and geysering in the risers. However, the timeline of these events are not well captured by the model. The model is also used to investigate the evolution of flow regime in the chimney. This work highlights that the semiempirical constitutive relations used in RELAP-3D could have a strong influence on the accuracy of the model in two-phase oscillatory flows.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2025

Dimensionless Regime Mapping and Chaos Analysis of Solids Volume Fraction Data in a Circulating Fluidized Bed Riser

Presentation of experimental results of solids volume fraction data measurements in a 12-inch diameter cold flow circulating fluidized bed in relation to a dimensionless fluidization regime map. Statistical and chaotic system analysis results are shown to illustrate differences in hydrodynamic behavior at different operating conditions. Presentation was made at the ASTFE 10th Thermal and Fluids Engineering Conference, March 09-12, 2025.

chaos↗
DOE OSTI2022

Learning functional priors and posteriors from data and physics

In this work, we develop a new Bayesian framework based on deep neural networks to be able to extrapolate in space-time using historical data and to quantify uncertainties arising from both noisy and gappy data in physical problems. Specifically, the proposed approach has two stages: (1) prior learning and (2) posterior estimation. At the first stage, we employ the physics-informed Generative Adversarial Networks (PI-GAN) to learn a functional prior either from a prescribed function distribution, e.g., Gaussian process, or from historical data and physics. At the second stage, we employ the Hamiltonian Monte Carlo (HMC) method to estimate the posterior in the latent space of PI-GANs. In addition, we use two different approaches to encode the physics: (1) automatic differentiation, used in the physicsinformed neural networks (PINNs) for scenarios with explicitly known partial differential equations (PDEs), and (2) operator regression using the deep operator network (DeepONet) for PDE-agnostic scenarios. We then test the proposed method for (1) meta-learning for one-dimensional regression, and forward/inverse PDE problems (combined with PINNs); (2) PDE-agnostic physical problems (combined with DeepONet), e.g., fractional diffusion as well as saturated stochastic (100-dimensional) flows in heterogeneous porous media; and (3) spatial-temporal regression problems, i.e., inference of a marine riser displacement field using experimental data from the Norwegian Deepwater Programme (NDP). The results demonstrate that the proposed approach can provide accurate predictions as well as uncertainty quantification given very limited scattered and noisy data, since historical data could be available to provide informative priors. In summary, the proposed method is capable of learning flexible functional priors, e.g., both Gaussian and non-Gaussian process, and can be readily extended to big data problems by enabling mini-batch training using stochastic HMC or normalizing flows since the latent space is generally characterized as low dimensional.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2022

Transient simulation of biomass combustion in a circulating fluidized bed riser

Interest in circulating fluidized bed (CFB) boilers as a power generation technology has sky-rocketed in recent years because of several advantages this technology offers over conventional boilers, such as increased gas-solid mixing, which results in higher combustion efficiency and the ability to use lower rank fuels. CFB combustors are operated at lower temperatures than conventional thermal power generation combustors, thus reducing NO x emissions, while SO 2 emissions can be conveniently controlled through the addition of Ca-based sulfur sorbents within the combustor. Herin this paper summarizes the modeling effort on a 50 kW th CFB combustor designed, built, and operated at CanmetENERGY in Ottawa, Canada. The numerical model employs the multiphase particle-in-cell (PIC) approach in the open-source Multiphase Flow with Interphase eXchanges (MFiX) Software Suite. The MFiX-PIC model parameters for the simulation are tuned against cold-flow experiments from CanmetENERGY using olivine sand as the inert bed material. It is shown that for the relatively coarse fluid meshes and large parcel sizes necessitated by the scale of the simulation, filter size dependent corrections to the drag law must be incorporated to ensure accuracy of the simulation results. The validated cold flow model is extended to simulate reacting flow with torrefied hardwood as the feedstock and to validate the combustion reaction scheme. The species concentrations at the riser outlet are compared against CanmetENERGY’s experiments and show satisfactory agreement. The simulations demonstrate the ability of MFiX-PIC to accurately capture both the physics and chemistry of a CFB combustor at bench scales, which can be further extended to pilot- and industrial-scale systems.

09 BIOMASS FUELS↗
DOE OSTI2022

FY22 Progress on Computational Modeling of the Water-Based NSTF

This report summarizes the system-level modeling effort by Argonne National Laboratory (Argonne) of the Natural convection Shutdown heat removal Test Facility (NSTF) in FY22. As an extension of the effort from FY21, this year’s work focuses primarily on the two-phase modeling of the NSTF using RELAP5-3D, particularly with the inclusion of the cavity model. The results from simulations were used to compare against experimental data for benchmarking purposes of the RELAP5 deck. Additionally, RELAP5 was used as a predictive tool to guide planned test operations and identify expected system behaviors. In the first part of this report, details are provided of the cavity omitted model where heat flux is applied directly as a boundary condition to the risers. The general trend predicted by the RELAP5 model matches that from the experimental data when a single-phase natural circulation flow is first established, followed by an oscillatory two-phase period and finally a stable two-phase flow. However, the onset of oscillations is predicted early by the model due to the smaller thermal mixing region in the tank. However, by expanding the simulated thermal mixing region in the tank, the onset of oscillations predicted by the model is able to match that from the experiment. These oscillations where studied in depth and are deduced to be flashing-induced instability. The model was then modified to simulate an accident scenario case where a representative heat load based on the full-scale Framatome’s 625 MW t SC-HTGR was applied directly to the riser channels. The simulated initial and boundary conditions were identical to those performed experimentally, facilitating direct comparisons between the predicted and experimental results. It was determined that the results showed some discrepancies remain, likely due to the overprediction of vapor generation rate by the computer model. In the second part of this report, the cavity model is re-introduced where it is observed that the RELAP5 prediction is now able to capture the major trends of the observed flow commonly observed during two-phase conditions. However, the onset of oscillations is once again predicted early by the model, possibly caused by the underprediction of heat loss from the heater and cavity. This is likely due to the omission of support structures in the cavity that can act as additional pathways for heat to escape to the environment. To overcome the underprediction of heat loss, part of the insulation surrounding the cavity side panels and the back of the heaters are removed to allow heat to escape directly to the environment, which then improves the RELAP5 prediction. Parametric studies are also performed to investigate the effects of heater power, tank inventory level, and tank gas space pressure on flow behaviors, also in direct comparison to conditions tested experimentally. User option-61 in the RELAP5-3D input deck, which changes the heat transfer coefficient correlations used for calculating the vapor generation, is also investigated where it is found that by enabling the option, the overall duration of oscillations is increased and matches that from the experiment better. The RELAP5 model is further benchmarked with a header inlet- throttling case where it is observed that the prediction from the model fails to capture some major features observed in the experiment. By using a modified loss coefficient curve for the valve, the accuracy of the prediction is improved where most of the major features observed in the experiment are predicted by the model. Lastly, the model is benchmarked with an inventory depletion scenario where it is observed that despite the modeling limitation of RELAP5, the prediction shows good agreement with the experimental data where major trends and features are captured by the model. Future work will see continued development of the current RELAP5-3D input deck of the NSTF to both improve the accuracy of the model’s predictive capability and continuing serving the experimental program. The mutually beneficial relationship between analysis and experimental efforts has become integral to the parent NSTF program, and the greater objective to fully understand and accurately predict the heat removal performance of a full scale RCCS concept.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2020

Biomass Combustion in a Circulating Fluidized Bed Combustor

Interest in circulating fluidized bed (CFB) boilers as a power generation technology has skyrocketed in recent years because of several advantages this technology offers over conventional boilers, such as increased gas-solid mixing resulting in higher combustion efficiency and the ability to use lower quality fuels. CFB combustors are operated at lower temperatures than conventional thermal power generation combustors, thus reducing NO x emissions. SO 2 emissions are conveniently controlled through the addition of Ca-based sulphur sorbents within the combustor. This report summarizes the current modeling effort on a 50 kW th CFB combustor with a diameter of 10 cm and a height of 5 m; designed, built, and operated at CanmetENERGY in Ottawa, Canada employing the multiphase particle-in-cell (PIC) approach in the open-source Multiphase Flow with Interphase eXchanges (MFiX) Software Suite. The MFiX-PIC model parameters for the simulation are tuned against cold-flow experiments from CanmetENERGY using 9 kg of olivine sand as the inert bed material. It is shown that for the relatively coarse fluid meshes and large parcel sizes necessitated by the scale of the simulation, filter size dependent corrections to the drag law must be incorporated to ensure accuracy of the simulation results. The validated cold flow model is extended to simulate reacting flow with torrefied hardwood as the feedstock and to validate the combustion reaction scheme. The species concentrations at the riser outlet are compared against CanmetENERGY’s experiments and show satisfactory agreement. The simulations demonstrate the ability of MFiX-PIC to accurately capture the physics and chemistry of a circulating fluidized bed combustor at bench scales, which can be further extended to pilot- and industrial-scale systems.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2021

Tank 49H Solids Disturbance Analysis

Tank 49H will serve as the feed tank for the Salt Waste Processing Facility (SWPF). Transfers into Tank 49H may disturb solids that have settled to the bottom of the tank, resulting in feed that may exceed the insoluble solids content limit of 1,200 mg/L from the SWPF Waste Acceptance Criteria (WAC). During a transfer into Tank 49H, material that free falls into Tank 49H through a downcomer and passes through the supernate could potentially disturb the solids on the bottom of the tank and scour or suspend solids from a settled solids layer or turbid region. A previous analysis and report evaluated the potential to disturb solids when transferring into Tank 49H through the B4 riser and recommended a minimum tank level of 120 inches to prevent disturbing any solids in the bottom of the tank. The scope of this task is to perform additional fluid flow analysis to determine the impact of a “plunging jet” through the C3 downcomer on solids in Tank 49H and to determine a minimum liquid level to be maintained in Tank 49H prior to transfers that will minimize disturbing the solids and exceeding the SWPF WAC limits for insoluble solids carryover to SWPF since the C3 riser downcomer is at a lower elevation and farther away from the B5 transfer pump than the B4 downcomer.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Tank 49H Solids Disturbance Analysis

Tank 49H will serve as the feed tank for the Salt Waste Processing Facility (SWPF). Transfers into Tank 49H may disturb solids that have settled to the bottom of the tank, resulting in feed that may exceed the insoluble solids content limit of 1,200 mg/L from the SWPF Waste Acceptance Criteria (WAC). During a transfer into Tank 49H, material that free falls into Tank 49H through a downcomer and passes through the supernate could potentially disturb the solids on the bottom of the tank and scour or suspend solids from a settled solids layer or turbid region. A previous analysis and report evaluated the potential to disturb solids when transferring into Tank 49H through the B4 riser and recommended a minimum tank level of 120 inches to prevent disturbing any solids in the bottom of the tank. The scope of this task is to perform additional fluid flow analysis to determine the impact of a “plunging jet” through the C3 downcomer on solids in Tank 49H and to determine a minimum liquid level to be maintained in Tank 49H prior to transfers that will minimize disturbing the solids and exceeding the SWPF WAC limits for insoluble solids carryover to SWPF since the C3 riser downcomer is at a lower elevation and farther away from the B5 transfer pump than the B4 downcomer.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗