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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 361 records · Page 20
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

On the 3D printing of polypropylene and post-processing optimization of thermomechanical properties

Polypropylene (PP) is a highly desirable polyolefin in various plastic industries due to its outstanding thermomechanical properties and chemical resistance. Therefore, the 3D printing of PP is an interesting avenue to explore in digitized manufacturing, where more freedom in structural designs is available for new and extended applications, such as high-performance engineering parts. Here, in this work, we 3D printed PP and studied the effect of printing parameters and post-processing conditions on the printed polymer’s thermomechanical behavior. Results showed that nozzle and bed temperatures of 220 and 100°C produced a high printing quality. Infill percentages between 80 and 90%, coupled with a 4-h annealing at 110ºC, also resulted in optimal printed properties. It is thought that PP can be potentially blended with polyethylene or other vinyl polymers for a more extended 3D printing utility and practical applications in rapid tooling and prototyping.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Exploration of Water Jets in Supersonic Crossflow Using X-Ray Diagnostics

Here, near-field structures of pure- and aerated-liquid jets injected into Mach 2 crossflow environments were experimentally investigated at the 7-BM beamline of the Advanced Photon Source at Argonne National Laboratory using high-speed shadowgraph imaging, high-speed x-ray imaging, and pathlength-integrated x-ray fluorescence. Liquid was flush injected into a blowdown supersonic wind tunnel. Test section top and side windows were fitted with a polycarbonate plate for high x-ray transmittance. An axisymmetric aerated-liquid injector was fitted with an exchangeable nozzle adaptor to generate a liquid jet. Water and nitrogen, the gas used for aerated-liquid jets, were doped with specially selected dopants to facilitate x-ray measurements. Liquid column structures for a pure-liquid jet, typically masked by dense droplet clouds in a supersonic crossflow environment, were visualized with the present x-ray imaging setup. Surface-wave formation, movement, and transformation on the column windward surface of the pure-liquid jet, along with column deformation and breakup processes, were qualitatively characterized. We measured time-averaged line-of-sight (LOS) liquid mass distributions within the liquid jet near fields. Cross-sectional liquid column contours of pure-liquid jets at various deformation stages were reconstructed from LOS liquid mass distributions. The pure-liquid jet deformed liquid column reached a maximum width of 1.47 times the orifice diameter before exhibiting rapid mass removal. We also observed the plume-crossing phenomenon in the aerated-liquid jet.

47 OTHER INSTRUMENTATION↗
DOE OSTI2022

Fluid Flow Observations of The Spray Near-Field Using High-Speed X-Ray Imaging

Sprays are important to may industrial processes, but the near-field region where spray formation takes place is difficult to visualize and characterize through visible light imaging because this region is typically optically dense. X-ray imaging is one technique that can penetrate this optically dense region and provide unique observations of the spray formation process. This study uses high-speed white beam X-ray imaging conducted at the Advanced Photon Source to capture spray formation dynamics from a canonical airblast atomizer. In this work, a range of momentum flux ratios are visualized by varying the gas flow rate while the liquid flow rate is held constant. The use of X-rays show overlapping flow structures including bags, ligaments, mushrooms, and webs. Air bubbles are captured within the liquid regions, and a very dynamic crown forms at the liquid needle exit at higher momentum flux ratios. Finally, at the highest momentum flux ratios, air bubbles and liquid droplets are observed migrating upstream in the center of the crown, and this motion is attributed to a toroidal recirculation cell at the nozzle exit.

47 OTHER INSTRUMENTATION↗
DOE OSTI1994

Nuclear Safety [Vol. 35, No. 2, July-December 1994]

Nuclear Safety is a journal that covers significant issues in the field of nuclear safety. Its primary scope is safety in the design, construction, operation, and decommissioning of nuclear power reactors worldwide and the research and analysis activities that promote this goal, but it also encompasses the safety aspects of the entire nuclear fuel cycle, including fuel fabrication, spent-fuel processing and handling, and nuclear waste disposal, the handling of fissionable materials and radioisotopes, and the environmental effects of all these activities. Table of Contents for this issue follows. GENERAL SAFETY CONSIDERATIONS: 179 Consideration of Postaccident Consequences in the Determination of Safety Objectives for Future Nuclear Power Plants in France, D. Queniart, A. Sugier, and J. Lochard; ACCIDENT ANALYSIS: 187 Nuclear Safety Research: The Phebus FP Severe Accident Experimental Program, P. von der Hardt, A. V. Jones, C. Lecomte, and A. Tattegrain; 205 Containment Performance Analysis of the Advanced Neutron Source Reactor at the Oak Ridge National Laboratory, S. H. Kim, R. P. Taleyarkhan, and V. Georgevich; 213 Assessment of Fission Product Deposits in the Reactor Coolant System: The DEVAP Program, G. Le Marois and M. Megnin; 222 Erratum to “A Review of the Available Information on the Triggering Stage of a Steam Explosion," Vol. 35, No. 1, CONTROL AND INSTRUMENTATION: 223 Effects of Normal Aging on Calibration and Response Time of Nuclear Plant Resistance Temperature Detectors and Pressure Sensors, H. M. Hashemian; DESIGN FEATURES: 235 Defense in Depth Against the Hydrogen Risk—A European Research Program, F. Fineschi; ENVIRONMENTAL EFFECTS: 246 Technical Note: A Preliminary Analysis of the Risks to Hong Kong Resulting from Potential Accidents of Daya Bay Nuclear Power Plant, Z. Shi and X. Wei; OPERATING EXPERIENCES: 253 Reactor Shutdown Experience, Compiled by J. W. Cletcher; SPECIAL SECTION ON TMI-2 VESSEL INVESTIGATION PROJECT: 256 Three Mile Island—New Findings 15 Years After the Accident A. M. Rubin and E. Beckjord; 269 Relocation of Molten Material to the TMI-2 Lower Head, J. R. Wolf, D. W. Akers, and L. A. Neimark; 280 Insight Into the TMI-2 Core Material Relocation Through Examination of Instrument Tube Nozzles, L. A. Neimark; 288 Physical and Radiochemical Examinations of Debris from the TMI-2 Lower Head, D. W. Akers and B. K. Schuetz; 301 Results of Metallographic Examinations and Mechanical Tests of Pressure Vessel Samples from the TMI-2 Lower Head, D. R. Diercks and G. E. Korth; 313 Margin-to-Failure Calculations for the TMI-2 Vessel, J. Rempe, L. Stickler, S. Chavez, G. Thinnes, R. Witt, and M. Corradini; U.S. NUCLEAR REGULATORY COMMISSION INFORMATION AND ANALYSES: 328 1993 Accident Sequence Precursor (ASP) Program Results, L. N. Vanden Heuvel, J. W. Cletcher, D. A. Copinger, J. W. Minarick, B. W. Dolan, and P. D. O’Reilley; RECENT DEVELOPMENTS: 339 Reports, Standards, and Safety Guides, D. S. Queener; 345 Proposed Rule Changes as of June 30, 1994; ANNOUNCEMENTS: 234 Thirty-First Annual Meeting of the National Council on Radiation Protection and Measurements; 356 1995 International Incineration Conference; 358 Fifth International Controls and Instrumentation Conference; 359 ANS International Topical Meeting on Safety of Operating Reactors; 359 Fifth International Conference on Nuclear Criticality Safety; 360 International Conference on Probabilistic Safety Assessment Methodology and Applications; 351 The Authors; 357 Reviewers of Nuclear Safety, Vol. 35.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2019

Understanding Transient Combustion Phenomena in Low-NO x Gas Turbines

The goal of this work was to understand, quantify, and eventually predict combustion instability during operational transients in low-NO x gas turbine combustors. Transient operation is defined as a mode where one or more key operating parameters, including equivalence ratio, fuel composition, or fuel splitting between nozzles in a combustor, are varying in time. The timescale over which this variation occurs will be referred to as the transient timescale, the magnitude of the change in the transient parameter will be referred to as the transient amplitude, and the direction of the variation will be referred to as the transient direction. Transients occur regularly in power generation gas turbine operation. For example, load-following gas turbines vary load to meet power demands while accounting for variation in unsteady grid contributors like wind and solar power. Operators achieve this by varying equivalence ratio and fuel splitting inside the combustors to produce more or less power. Another example of transient operation is during fuel-switching operations, a particular issue for turbines operating with syngas fuels in a co-generation facility. In this case, the composition of the fuel stream may vary in time either as a result of fluctuations in the pipeline, or in the case of a co-generation plant, variations in feedstock or gasification processes. This fluctuation in fuel composition can have significant implications for combustion processes, particularly with high-hydrogen fuels. A small number of studies have investigated transient behavior in gas turbine combustors, particularly in the context of flame blow-off; here, investigators have typically focused on issues of transient amplitude, though without the depth and physics-based experimental design that is proposed in this program. To our knowledge, there have been no studies that have quantified the impact of the transient timescale on combustion. The work helped us understand the impact of several types of transients on combustion stability. Both static and dynamic combustion stability will be considered. The transients will be quantified using their amplitude, direction, and timescale, and we will consider transients in equivalence ratio, fuel composition, and fuel splitting. There were two main objectives of this work: 1. Provide a fundamental understanding of combustion stability during transient operation using data obtained from a number of high-speed diagnostic techniques on experimental configurations that capture important gas turbine combustor features and operating conditions. This goal was met in conjunction with our industrial partner, GE Global Research, with whom we worked closely throughout the program. 2. Develop a stability prediction framework that will allow for the prediction, and possible control, of instabilities as a function of the transient amplitude, direction, and timescale. This input/output model should be physics-based and allow for screening of operating conditions and prediction of unstable behavior at the end of a transient by monitoring combustor health and precursor signals during operation.

03 NATURAL GAS↗
DOE OSTI2020

Nuclear Thermal Propulsion Scoping Analysis of Fuel Plate Core Configurations

Nuclear thermal propulsion (NTP) engines use a nuclear reactor to heat up hydrogen to high temperatures. Thrust is generated as the hydrogen is ejected at high velocity through a nozzle. NTP has the potential of reducing travel times for deep space missions, such as to Mars. The United States studied NTP early in the space age and the National Aeronautics and Space Administration (NASA) is currently revisiting the potential of the technology to enable its missions.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

Atomic kinetics of laboratory photoionized plasmas relevant to astrophysics. Final report

The major goal of this project was to study the atomic and radiation physics of photoionized plasmas driven by a broadband x-ray flux and its impact on plasma x-ray heating and ionization, emissivity and opacity, and radiation-hydrodynamics. This problem is relevant to the physics of accretion disks surrounding black holes, x-ray binaries, and active galactic nuclei in astrophysics. In addition, it is also important for understanding non-equilibrium laboratory plasmas driven by a distribution of photons. To this end, and motivated by previous and ongoing gas-cell experiments performed by the PI at the Z facility of Sandia National Laboratories, we developed a new experimental platform at the 1MA Zebra pulsed power accelerator of the University of Nevada, Reno based on using a gas jet produced by a supersonic nozzle. The gas jet is turned into a photoionized plasma driven by the x- ray flux from a wire-array z-pinch. Establishing this new experimental platform at Zebra was a major goal of this project. In addition, we have also dedicated effort to continue complementary experiments at the Z facility using the gas-cell photoionized plasma set up with support from the Fundamental Science Program at Z as well as to perform data processing and analysis, and theory and modeling simulations, including electron kinetics and radiation-hydrodynamics. Since we seek to test and establish what physics models are needed to describe photoionized plasma guided by experimental observation, these complementary experimental efforts were central to achieving the goals of this project.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Discrete Element Method Analysis for Metal Powders Used in Additive Manufacturing, and DEM Simulation Tutorial Using LIGGGHTS-PUBLIC [PowerPoint and paper]

Discrete Element Method (DEM) is a method of analysis to evaluate the dynamic interactions between granular particles. This method has been used in the pharmaceutical industry to improve the powder compaction process for tablet manufacturing. There are also applications in agriculture, food industry, and manufacturing. Direct energy deposition is an additive manufacturing technique which uses metallic powders fed through a nozzle, melted using a directed laser, and transformed into a solid object layer by layer. One way of feeding metal particles into the system involves the use of a vibrating hopper. Given a specified amplitude and frequency input, the hopper will enable the powder to travel up a path, and inject through the system with assistance from a stream of gas. The mechanical properties of a printed object can vary, depending on the characteristics of the powder flow and the particles’ as-received properties. Improved understanding of dynamic interactions of flowing powders could enable additive manufacturing components with 2D or 3D variations in mechanical properties, e.g., density. This work uses DEM simulation software to investigate the effects of particle cohesion, friction, and density on the quality of the flow by performing an angle of repose simulation, which is often used as a metric to evaluate the flowability of powders.

36 MATERIALS SCIENCE↗
DOE OSTI2020

Materials response under hypersonic flow conditions probed by multi-modal diagnostics in a benchtop wind tunnel

In this LDRD “Materials response under hypersonic flow conditions probed by multi-modal diagnostics in a benchtop wind tunnel” a peer-reviewed lab-scale hypersonic wind tunnel (WT) was planned to be assembled in-house, along with time and space resolved and related flow and materials diagnostics to derive high quality measurements and the science that is able to inform the development of our modeling and simulation codes for the hypersonic regime. The baseline capability to achieve Mach 3 flow was scheduled to be completed in Q4 2020, in the first year of the LDRD. However due to the COVID-19 delays and travel restrictions starting in March, 2020 this task could not be completed to carry out the materials response studies in-house, or those planned with external partners that were engaged during this LDRD (NASA Langley, NASA Ames, Texas A&M university, and Virginia Tech). Still, using our hypersonic computational fluid simulation codes, many of the hypersonic components have been designed (for Mach 3, 5, and 7) and procured (or in procurement phase), and a new dedicated hypersonic laboratory was facilitized, 2 WT test sections have been manufactured, and a Mach 3 nozzle was 3D printed for prototyping. In parallel, unique materials diagnostics have been tested under static conditions and fully specified and awaiting validation in our partner facilities. Due to the new hypersonic initiative announced in January, 2020 we proposed a related scope increase in hypersonics research requiring energy interactions and new diagnostics well beyond what could be supported by an LDRD ER. A decision was made to end the current LDRD ER and formally propose a new LDRD SI that leverages the current effort, which will be starting in FY21. As a result of the uniqueness of this LDRD work, our early efforts have been encouraged and well received in the hypersonic research community, and is now part of multiple unsolicited internal and external project proposals expected to be funded in the coming years, which is encouraging to make LLNL a leader in experimentally probing extreme physics of local energetics critical to hypersonics.

36 MATERIALS SCIENCE↗
DOE OSTI2021

HSLA-100 Forging Contract Vendor Post-Award Meeting [Slides]

LANL utilizes thick-walled, spherical vessels for numerous basic science, materials, and system performance experiments. These pressure retaining vessels are designed and fabricated to meet the intent of ASM E B&PV Section VIII, Division 3 and Code Case 2564. LANL has successfully contracted past production of component parts (nozzle and cover forgings, plate production and head forming) and overall vessel construction (welding, inspection, hydrostatic testing) utilizing HSLA-100 steel. As current vessel inventories approach design lifetimes, we are once again embarking upon a series of fabrication contracts to produce replacement components and vessel assemblies to ensure continued experiment cadence at LANL. We anticipate releasing additional future vessel production contracts as experimental demands at LANL continue to increase

36 MATERIALS SCIENCE↗
DOE OSTI2021

Terry Turbopump Expanded Operating Band Modeling and Simulation Efforts in Fiscal Year 2021 Extended Period of Performance (Final Report)

This report documents the progress made under the Terry Turbine Expanded Operating Band (TTEXOB) program's modeling and simulation (MODSIM) initiative at Sandia National Laboratories (SNL ). It describes the US Federal Fiscal Year 2021 (FY21) extended period-of-performance MODSIM work completed since the closure of FY20 with due reference to the Texas A&M University (TAMU) hybrid milestone 5/6 experimental program. This work, which falls under Milestone 7 of the program, provides a counterpart to the various experiments. The overall TTEXOB program and its milestone-based approach are described in the program's Summary Plan. Details of the individual milestone test plans can be found in the corresponding detailed test plan, e.g. the Milestone 3 and 4 Detailed Test Plan. SNL MODISM is conducted alongside experiments performed at TAMU, and SNL technical staff regularly consults with TAMU on the experimental program. In FY21, MELCOR code models and capabilities were exercised in two different contexts: experimental comparisons to the TAMU ZS-1 and GS-2, and stand-alone analyses of a station black-out (SBO) scenario in a generic boiling water reactor (BWR). Code to experiment comparisons met with fair success when turbine losses were well characterized as for the ZS-1 turbine. Both deterministic and Bayesian calibration processes were used to find a recommended turbine torque multiplier for ZS-1 type turbines. This process could be repeated for GS-2 type turbines if GS-2 losses were better understood. Stand-alone generic BWR SBO calculations revealed that three different modes of self-regulating turbopump behavior may be observed depending on certain modeling parameters and choices having to do with turbine nozzles. Aspects of this predicted behavior may have been observed in TAMU GS-2 experiments.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2021

Effect of thermal aging and irradiation on microstructure and crack growth response of Alloy 690

Nickel-base Alloy 690 and the associated weld Alloys 52 and 152 are typically used for nozzle penetrations in replacement heads for pressurized water reactor (PWR) vessels, because of their excellent overall resistance to general corrosion and environmental degradation, primarily stress corrosion cracking (SCC). However, many of the existing PWRs reactors are expected to operate for 40-80 years. Likewise, advanced water-cooled small modular reactors (SMRs) will use Ni-Cr alloys and are expected to receive initial operating licenses for 60 years. Hence, the thermal stability of Ni-Cr alloys is a potential concern for the long-term performance of both existing and advanced nuclear plants, and possibly spent fuel storage containers. The objective of this research is to understand the microstructural changes occurring in high-Cr, Ni-based Alloy 690 during long time exposure to the reactor operating temperatures, and the effect of these changes on the service performance. One area of particular concern is the potential for long range ordering (LRO), i.e. formation of the intermetallic Ni 2 Cr phase under prolonged exposure to reactor temperatures and/or irradiation, which can increase strength, decrease ductility, and cause dimensional changes or lead to in-service embrittlement of components made with these alloys. Hence, this research focused on the microstructural evolution and the SCC response of Alloy 690 under accelerated thermal aging and irradiation conditions. The materials studied involved Alloy 690 from two sources: (i) Alloy 690 plate from an Alloy 152 dissimilar metal weld (DMW) joining the Alloy 690 plate to Alloy 533 LAS, aged at three different temperatures (370°C, 400°C and 450°C) for up to 75,000h (equivalent to 60 years of service), and (ii) specimens neutron-irradiated in the BOR-60 reactor up to 40 dpa. For aged Alloy 690 specimens, hardness was found to increase with aging time, however, the microstructural characterization by means of synchrotron X-ray did not find evidence of LRO. The microstructural characterization of neutron-irradiated specimens by TEM found no evidence of LRO either. Testing in a primary water environment of Alloy 690 specimens aged to a 60-year service equivalent revealed a fatigue and corrosion fatigue crack growth responses similar to those measured on the un-aged alloy. The SCC CGR response was also low. Overall, the two Alloy 690 heats investigated in this work, aged up to 60-year service equivalents or exposed to neutron irradiation up to 40 dpa, did not exhibit a deterioration in microstructure or performance.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2020

BWR Spent Nuclear Fuel Acquisition and Testing to Support DOE-NE High Burnup Spent Fuel Data Project

The Office of Spent Fuel and Waste Disposition (SFWD) within the US Department of Energy (DOE) Office of Nuclear Energy (NE) established the Spent Fuel and Waste Science and Technology (SFWST) campaign to conduct research and development (R&D) activities related to the storage, transportation, and disposal of spent nuclear fuel (SNF) and high-level radioactive waste. The SFWST program was created within SFWD to address issues of extended or long-term SNF storage and transportation. Some near-term objectives of SFWST are to use a science-based, engineering-driven approach to: Support the enhancement of the technical bases to support the continued safe and secure dry storage of SNF for extended periods; Support the enhancement of the technical bases for retrieving SNF after extended dry storage; Support the enhancement of the technical bases for transporting high burnup (HBU) fuel and transporting low burnup fuel and HBU fuel after dry storage DOE-NE, in partnership with the Electric Power Research Institute, developed the High Burnup Spent Fuel Data Project to perform a large-scale demonstration and laboratory-scale testing of HBU pressurized water reactor (PWR) fuels (exceeding 45 gigawatt-days per metric ton of uranium [GWd/MTU]). Under this project, 25 sister rods—which are rods that have the same design, power histories, and other characteristics—were removed from assemblies at the North Anna Nuclear Power Station and sent to Oak Ridge National Laboratory (ORNL) in January 2016. ORNL performed detailed nondestructive examination (NDE) on all 25 rods. The NDE consisted of visual examinations, gamma and neutron scanning, profilometry and rod length measurements, and eddy current examinations. After completing the NDE, 10 of the sister rods were delivered to Pacific Northwest National Laboratory (PNNL) in a NAC International, Inc. legal-weight truck cask in September 2018 for destructive examination (DE). To date, SFWD work has focused on the PWR fuel that is part of the Sister Rod Test program. No boiling water reactor (BWR) fuel has been tested in the program, and the data needs that were identified for the PWR fuel have not been collected for BWR fuel. The goal to obtain six to nine BWR rods and test them at ORNL will support closing this important data gap. BWR fuel comprises approximately 56% of the total fuel assemblies currently in storage at nuclear power plants in the United States. BWR nuclear fuel and cladding designs and manufacturing are significantly different from PWRs. Differences include the following: BWR fuel pellets are larger than PWR pellets; Variations of Zircaloy-2 (including liners) are used instead of the Zircaloy-4 cladding materials used in PWRs; Clad manufacturing and stress-relief processes are different between PWRs and BWRs; The fuel rod dimensions are different because larger rod diameters and thicker cladding are used in BWRs; BWR fuel typically has lower internal rod pressures and sees vastly different operating conditions than PWR fuel (i.e., two-phase flow); BWR assemblies are “canned,” meaning each assembly is surrounded by a metal fuel channel; BWR cladding is often composed of an inner pure Zr liner that has widely different mechanical properties than the Zircaloy-2 alloy and exhibits a stronger affinity for hydrogen; The BWR SNF generally has more total hydrogen in the cladding/liner than typical PWR fuel; The construction of the PWR and BWR assemblies is vastly different; BWR rods are solidly attached to the assembly nozzles and experience a much different vibration and shock load than PWR rods, which are “floating” within a grid system attached to guide tubes, and the rods sit loosely on the bottom end plates. These numerous differences will affect the way the BWR SNF responds under dry storage preparation processes (e.g., vacuum drying) and during transportation. The results collected in the PWR experimental program must be compared with a subset of similar data collected on BWR SNF to establish a technical basis for whether the larger PWR database is sufficient to bound the BWR SNF end-of-life conditions as is currently assumed for several fuel/clad properties. Changes that occur in both fuel types at HBU could exacerbate any mechanical property differences. As the fuel burnup increases, several changes occur that might affect the performance of the fuel, cladding, and assembly hardware in storage and transportation. These changes include increased cladding corrosion layer thickness, increased cladding hydrogen content, increased cladding creep strains, increased fission gas release, and the formation of the HBU structure at the surface of the fuel pellets. The Nuclear Regulatory Commission (NRC) limits the current maximum rod-averaged burnup to 62 GWd/MTU due to these changes and the lack of data at higher burnups.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2021

High Temperature Thermal Barrier Coating Evaluation of Yttrium Aluminum Garnet for Gas Turbine Applications

The Solution Precursor Spray Process (SPPS) process has been shown to overcome the durability and property challenges of applying yttrium aluminum garnet (YAG) coating for high temperature thermal barrier coating (TBC) applications (1200°C+) but only limited testing has been performed in representative application environments. In this study, YAG coatings were developed to optimize microstructure and tailor properties for combustion components in an industrial gas turbine. Thermal conductivity, erosion resistance and furnace cycling durability were used to validate YAG properties against the standard yttria-stabilized zirconia coating (YSZ). Graded and multi-layered microstructures were applied to enhance performance while maintaining durability. Further YAG process development was required to replicate coating properties and optimize deposition on more complex fuel injector nozzle and combustion liner components. Rig testing of both components was performed and compared against the baseline YSZ coating validating the high temperature capability and lower thermal conductivity of the SPPS YAG coating. The components in both tests were cycled for a minimum of ten cycles with the fuel injector test targeting a higher operating temperature while the combustor liner operated at standard conditions. A development engine test is planned to further validate performance in a gas turbine engine of this promising material.

36 MATERIALS SCIENCE↗
DOE OSTI2021

System Configuration Evaluation for Process Settling of Hanford Waste Solid Particles

Direct Feed High-Level Waste (DFHLW) is a potential flowsheet operations approach to initiating high-level waste (HLW) vitrification prior to completion of the Hanford Waste Treatment and Immobilization Plant (WTP) Pretreatment Facility. A settle/decant process has been proposed to concentrate solids prior to delivery to the WTP HLW Facility during DFHLW operations, wherein the solids in a settled layer would be remixed with the supernatant liquid remaining after decanting operations to provide the feed at required solids concentrations. Settling would be used in lieu of purpose-built filtration or other solids separation equipment. Pacific Northwest National Laboratory (PNNL) is providing baseline technical support to the Washington River Protection Solutions (WRPS) Flowsheet Integration group. To support planning for DFHLW, WRPS previously requested that PNNL evaluate the current data set available to predict the time needed for HLW solids to settle and the solids concentration and strength of that settled layer, to identify gaps in the understanding and predictive capability of HLW solids waste settling times, and to provide scoping estimates of the potential settling times. Eight technical gaps were identified for predicting settling times and characteristics of the formed sediment layers. In addition to the data gaps, an overarching observation was made that there is significant variation in behavior of settling rate and settled layer data. The settling time required to concentrate solids via a settle/decant process was determined from the limited data to have a difference of potentially more than a factor of 5,000 in the estimated settling times, varying from 0.2 to 1,060 days for example depending on process vessel depth and final sediment solids concentration. In contrast, successful processes of liquid-forward output streams resulting from in-tank settling and decanting forward liquid have been reported for operations conducted at the Hanford Site. The purpose of this current report is to further support DFHLW planning by evaluating double-shell tank (DST) and alternate vessel equipment and operational configurations to enable optimization of the settle/decant process to concentrate solids. Hanford waste processing behavior specific to liquid feed availability following a slurry transfer in a DST is summarized, including process stream characteristics and process equipment configurations. The performance of DST process equipment configurations is evaluated for possible improvements using computational fluid dynamics (CFD) and simple analytical models. Potential new vessel design(s) specific to enabling effective settle/decant processes, and cursory summary of other separate and inline solids separations processes, are also provided. The CFD results indicated that improvement in outflow solids concentration was promoted by a reduction in the slurry flow rate, angling the distributor nozzles downward, and lifting the transfer pump. The solid-liquid analysis evaluating particle trajectory confirmed that the potential for particle ingestion (in the transfer pump) was decreased with increased radial separation between the inlet and outlet (transfer pump inlet), decreased inlet flow, and decreased liquid density and viscosity for a neutrally buoyant inlet flow. An assessment was also made of the potential for inflow configuration changes to result in the discrete mounding or piling of solids within the tank. Based on the characterization of the settled waste to date, HLW sediments will be unlikely to sustain a substantial angle of repose to facilitate significant variations in the elevation of the settled solids.

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

MFIX DEM Enhancement for Industry-Relevant Flows (Final Report)

The overall goal of this two-phase project is to implement performance improvements of the Multiphase Flow with Interphase Exchanges (MFIX) Discrete Element Model (DEM) code that enable a transformative shift for industrial use. Prior to this effort, the largest simulations performed using MFIX are O(10 7 ) particles. This falls short of the O(10 9 ) particle simulations that must be completed on a timescale of days or weeks (vs. months or years) to enable simulations with physically-relevant domain sizes to be incorporated into industrial design cycles within five years. This was accomplished by tailoring best-in-class practices to bear on the unique challenges posed by the MFIX-DEM algorithm and code base. Scientific simulations (e.g., in cosmology, turbulent combustion) routinely use massively parallel computing to update far more particles in short wall clock times. Results from Phase 1 (1.5 years in duration) indicated significant gains in speed were possible for a wide range of benchmark cases. Moreover, a survey sent to >35 companies indicates that the timing is ideal for such an enhanced tool, with >80% of the respondents indicating that DEM is already value-added or will be within the next 5 years, and >70% of the respondents indicating that improved speed is the top computational priority. In Phase 2 (3.5 years in duration), the two major barriers that hinder industry from effectively using multiphase Computational Fluid Dynamics (CFD) to cut costs and improve performance, namely computational overhead and confidence in predictions, continued to be addressed. Regarding the former, the results from Phase 1 to guide the effort, with enhancements focused on an improved time-stepping algorithm and particle sorting. Four target problems of 1 billion particles each and increasing complexity were identified: homogeneous cooling, tumbler with continuous particle size distribution, discharge from a rectangular hopper and a cylindrical riser. Each of these were successfully simulated for relevant time scales (on order of seconds) using less than 24 hours of wall clock time. These represent the first 1-billion particle DEM simulations performed with MFIX, namely using the MFIX-Exa code. This code is currently under development at NETL in collaboration with Lawrence Berkeley National Laboratory. Regarding the second barrier on predictive uncertainty, experiments from Phase 1 (interacting nozzles - hydrodynamics only) and Phase 2 (very small-scale segregation experiments) were used to demonstrate the ability of two simplified approaches to uncertainty quantification (UQ). By limiting the number of particles, UQ based on the simplified treatment was compared to standard UQ, which was shown to have much higher computational demands. Experiments were also performed on a pilot-scale stripper unit to provide validation data for future CFD-DEM simulations and UQ.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2022

Cooperative Research and Development Agreement between National Energy Technology Laboratory and Princeton University (Abstract)

The National Energy Technology Laboratory (NETL) and Princeton University will collaborate in the development of microwave-plasma technology to convert methane into hydrogen and valuable solid carbon materials. The effort will combine NETL’s vast resources for microwave-enhanced process development, characterization, and design with Princeton University’s extensive expertise in the study of non-equilibrium plasmas employing supersonic nozzles. Lab-scale experiments will be conducted for different conditions to convert and compare their respective performance in hydrogen production. Computational modeling will be performed to verify results from experimental studies conducted in both labs.

08 HYDROGEN↗
DOE OSTI2022

Materials for Advanced Ultra-Supercritical (A-USC) Steam Turbines --- A-USC Component Demonstration

The U.S. Advanced Ultra-Supercritical (A-USC) Consortium was formed in 2001 as a government/industry program, sponsored by the U.S. Department of Energy (DOE) and the Ohio Coal Development Office (OCDO) and cost shared by industrial and not-for-profit partners. The purpose of the consortium was to advance the state of the art for power generation by evaluating and developing materials that allow the use of advanced steam cycles in coal-based power plants. These advanced cycles, with steam temperatures up to 1400°F (760°C), can increase the efficiency of coal-fired boilers from an average of 35% (current U.S. fleet) to more than 45% higher heating value (HHV) (>49% lower heating value [LHV]). The increase in a plant’s efficiency is limited unless new materials able to withstand these higher operating temperatures and pressures are identified and approved for use. The A-USC Consortium identified these needed materials during earlier phases of the program. It developed the welding and joining techniques along with manufacturing processes for casting and wrought products made from these new high-nickel alloys. It subjected these materials to extensive laboratory and steam loop testing. It then obtained ASME code approval for their use in U.S. boiler systems. The program’s successes leave this last remaining activity (ComTest Phase 2) that the U.S. utility industry has recommended to be accomplished prior to commercialization. The focus of the activity is the evaluation and demonstration of commercial readiness for “full scale” components to be made from these nickel-based alloy materials and provided by a U.S. domestic supply chain that is new to working with these alloys. According to studies completed by the Electric Power Research Institute (EPRI), the cost of an A-USC plant is approximately 20% higher than a non-A-USC plant because of its use of nickel-based alloys needed for the high temperature operating conditions. However, CO 2 reductions of approximately 30% from the current fleet average provide a strong incentive for its consideration. The actual costs and perceived value for CO 2 abatement will determine whether new or retrofitted plants are undertaken, although decisions to build A-USC plants in India would indicate its economic feasibility while also being part of a global carbon emissions strategy. The work by the A-USC Consortium, prior to the start of the ComTest project, has included lab scale and pilot scale materials testing, both in air and oxy-combustion. This testing has included air-cooled and steam-cooled “loops” that were installed into existing operating utility boilers to gain exposure of these materials to realistic conditions of high temperature and corrosion caused by the constituents in the coal ash. The A-USC Consortium also gained ASME Code approval of the Inconel 740 material, has cast and extruded the largest high nickel precipitation hardened alloys, and developed unique welding techniques to avoid problems identified by the competing European program. However, as valuable as these material test loops and accomplishments have been for obtaining information, their scale is below that required to minimize the risk associated for a U.S. utility to build a multibillion-dollar A-USC power plant. To reduce the final identified risk barrier to full-scale commercialization of these advanced materials and systems, the A-USC Consortium (guided by a utility industry advisory committee) has identified the key areas of the technology they desire to see as being capable of full-scale manufacturing and/or fabrication from an identified, capable U.S. domestic supplier base. A significant amount of work was accomplished during Phase 1 to identity the components, as well as the component size, that would be manufactured from advanced alloys such as Inconel 740H or Haynes 282 alloys. Pathways to supply these components for ComTest have been identified, as well as any further development that would be required. The Phase 2 effort used Phase 1 findings for designing these key full-scale components for A-USC boilers and turbines to include large castings; extrusions, forgings, fabrication of water walls and steam loops with headers from advanced materials, raw material (such as pipe extrusion billets) are at the commercial readiness level to permit advancement to a demonstration project. The Phase 2 work scope was addressed by a diverse team, including government, industry, and not-for-profit partners. The work scope under Phase 2 addressed fabrication of components identified as being outside of the proven capabilities of the existing supply chain, including the following: Steam turbine rotor forging and Haynes 282 nozzle carrier casting Superheater and reheater header and tube assemblies Large-diameter pipe extrusions and forgings Test valve articles to support ASME Code approval. In addition, key fabrication steps were completed, including boiler weld overlays and simulated field repairs. Throughout, extensive inspection and quality assurance testing of the components were performed. The team worked to advance ASME Code approval for key components and processes. Although much of the focus of ComTest Phase 2 was the high-temperature nickel-based alloy materials, a broader range of materials were incorporated, which would be representative of the materials used in full-scale A-USC power plant applications and have cross-cutting applicability on other high-temperature power generation options, such as advanced nuclear, supercritical CO 2 cycles, and central solar receivers. This report that has been submitted is organized in the following manner: Section 1 contains an Executive Summary. Section 2 discusses the ComTest project background and organization. Section 3 discusses project management and reporting. Section 4 discusses the procurement of nickel-based alloy and other A-USC materials and components. Section 5 discusses the fabrication of procurement of nickel-based alloy and other A-USC materials and components. Section 6 discusses the fabrication of cast nickel-based A-USC steam turbine components. Section 7 discusses the fabrication of forged nickel-based A-USC steam turbine piping and steam pipe components. Section 8 discusses the qualification of pressure relieve valves (PRVs) for A-USC power plants. Section 9 discusses proposed plans for future evaluation of A-USC components. Section 10 contains the summary and conclusion.

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