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DOE OSTI2012

Keeping Energy Savings in the LOOP

Mesa Lane Partners (MLP) partnered with the U.S. Department of Energy (DOE) to develop and implement solutions to a build a new, low-energy mixed-use building that consumes at least 50% less energy than requirements set by Energy Standard 90.1-2007 of the American Society of Heating, Refrigerating, and Air-conditioning Engineers (ASHRAE), the American National Standards Institute (ANSI), and the Illuminating Engineering Society of America (IESNA), as part of DOE’s Commercial Building Partnerships (CBP)3 Program. Lawrence Berkeley National Laboratory (LBNL) provided technical expertise in support of this DOE program. The privately developed 46,000-square-foot LOOP project, which is intended to provide affordable off-campus student housing in an underserved community next to University of California at Santa Barbara, will contain more than 7,000 square feet of retail space, a roof deck, an event space, a gym, and 48 apartments. The project developer, MLP, is aiming to exceed CBP requirement, targeting energy consumption that is at least 65% less than that required by the standard. If the LOOP meets this goal, it is expected to achieve Leadership in Energy and Environmental Design (LEED) Gold certification. To meet this goal, the project design incorporates a variety of energy efficiency measures (EEMs) that address the needs of the multiple use types that the project will house.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2012

Achieving Energy Savings in Municipal Construction in Long Beach, CA

Long Beach Gas and Oil (LBGO), the public gas utility in Long Beach, California, partnered with the U.S. Department of Energy (DOE) to develop and implement solutions to build a new, low-energy modular office building that is at least 50% below requirements set by Energy Standard 90.1-2007 of the American Society of Heating, Refrigerating, and Air-conditioning Engineers (ASHRAE), the American National Standards Institute (ANSI), and the Illuminating Engineering Society of America (IESNA) as part of DOE’s Commercial Building Partnerships (CBP) program.3 The LBGO building, which demonstrates that modular construction can be very energy efficient, is expected to exceed the ASHRAE baseline by about 45%. The new 15,000-square foot (ft2) LBGO office building has two stories and houses private offices, open-plan cubicle offices, and a conference room and call center on the second floor. The building’s modular nature allowed LBGO to realize the cost benefits of fasttracked construction while saving substantial energy and reducing operational costs. The project was funded by the utility’s ratepayer revenue, which imposed a tight budget limit. The design process was a collaborative effort involving LBGO and its design-build team, Lawrence Berkeley National Laboratory (Berkeley Lab), and subcontractors Stantec (formerly Burt Hill) and LHB Inc. The team proposed efficiency measures based on computer modeling of the building in full compliance with ASHRAE 90.1-2007; in the modeled building, the lighting and cooling systems were the largest energy users, so increasing the efficiency of these systems was a top priority. Promising measures were modeled to estimate their energy performance, and each measure was evaluated for its feasibility within the budget.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2015

Inductively Driven, 3D Liner Compression of a Magnetized Plasma to Megabar Energy Densities

To take advantage of the smaller scale, higher density regime of fusion an efficient method for achieving the compressional heating required to reach fusion gain conditions must be found. What is proposed is a more flexible metallic liner compression scheme that minimizes the kinetic energy required to reach fusion. It is believed that it is possible to accomplish this at sub-megajoule energies. This however will require operation at very small scale. To have a realistic hope of inexpensive, repetitive operation, it is essential to have the liner kinetic energy under a megajoule which allows for the survivability of the vacuum and power systems. At small scale the implosion speed must be reasonably fast to maintain the magnetized plasma (FRC) equilibrium during compression. For limited liner kinetic energy, it becomes clear that the thinnest liner imploded to the smallest radius consistent with the requirements for FRC equilibrium lifetime is desired. The proposed work is directed toward accomplishing this goal. Typically an axial (Z) current is employed for liner compression. There are however several advantages to using a θ-pinch coil. With the θ-pinch the liner currents are inductively driven which greatly simplifies the apparatus and vacuum system, and avoids difficulties with the post implosion vacuum integrity. With fractional flux leakage, the foil liner automatically provides for the seed axial compression field. To achieve it with optimal switching techniques, and at an accelerated pace however will require additional funding. This extra expense is well justified as the compression technique that will be enabled by this funding is unique in the ability to implode individual segments of the liner at different times. This is highly advantageous as the liner can be imploded in a manner that maximizes the energy transfer to the FRC. Production of shaped liner implosions for additional axial compression can thus be readily accomplished with the modified power modules. The additional energy and switching capability proposed will thus provide for optimal utilization of the liner energy. The following tasks were outlined for the three year effort: (1) Design and assemble the foil liner compression test structure and chamber including the compression bank and test foils [Year 1]. (2) Perform foil liner compression experiments and obtain performance data over a range on liner dimensions and bank parameters [Year 2]. (3) Carry out compression experiments of the FRC plasma to Megagauss fields and measure key fusion parameters [Year 3]. (4) Develop numerical codes and analyze experimental results, and determine the physics and scaling for future work [Year 1-3]. The principle task of the project was to design and assemble the foil liner FRC formation chamber, the full compression test structure and chamber including the compression bank. This task was completed successfully. The second task was to test foils in the test facility constructed in year one and characterize the performance obtained from liner compression. These experimental measurements were then compared with analytical predictions, and numerical code results. The liner testing was completed and compared with both the analytical results as well as the code work performed with the 3D structural dynamics package of ANSYS Metaphysics®. This code is capable of modeling the dynamic behavior of materials well into the non-linear regime (e.g. a bullet hit plate glass). The liner dynamic behavior was found to be remarkably close to that predicted by the 3D structural dynamics results. Incorporating a code that can also include the magnetics and plasma physics has also made significant progress at the UW. The remaining test bed construction and assembly task is was completed, and the FRC formation and merging experiments were carried out as planned. The liner compression of the FRC to Megagauss fields was not performed due to not obtaining a sufficiently long lived FRC during the final year of the grant. Modifications planned to correct this deficiency included a larger FRC source as well as a much larger liner driver energy storage system. Due to discontinuation of the grant neither of these improvements were carried out.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2015

Zero Degree Line Mo Target Thermal Test Results and Analysis

Target testing at 35 and 42 MeV was completed on January 14, 2015. At 35 MeV the current was varied from 177 to 375 μA with helium mass flow rate varied from 45 up to 101 g/s. At 42 MeV only one current, 170 mA, was tested because of accelerator performance limitations. The target design for this test, and the subsequent production tests, is largely unchanged from the earlier design for ANL beam tests at lower energy and higher current, comprised of 25 Mo disks 1 mm thick spaced 0.5 mm apart for helium coolant flow gaps. Disks are 12 mm diameter, with expected beam size 6 mm FWHM. Because the target, particularly the window, was designed for lower energy and higher current, the intercepted beam (beam heating) was much less during these tests. Therefore, the thermal stress and, more importantly, reduction in material strength resulting from high temperature, was not a limiting concern. The intended result of the thermal test is to measure heat transfer as a function of helium mass flow rate. Heat transfer coefficient was determined by the measurement of temperature at the center of the first 8 Mo disks while varying helium flow rate and beam current. The performance was then compared to predictive tools: Heat transfer correlations in the literature and finite element analysis using ANSYS

42 ENGINEERING↗

DOE OSTI2015

Tenth Interim Status Report: Model 9975 O-Ring Fixture Long-Term Leak Performance

42 ENGINEERING↗

DOE OSTI2015

Model 9975 O-Ring Fixture Long-Term Leak Performance (Tenth Interim Status Report)

A series of experiments to monitor the aging performance of Viton® GLT O-rings used in the Model 9975 package has been ongoing since 2004 at the Savannah River National Laboratory. One approach has been to periodically evaluate the leak performance of O-rings being aged in mock-up 9975 Primary Containment Vessels (PCVs) at elevated temperatures. Other methods such as compression-stress relaxation (CSR) tests and field surveillance are also on-going to evaluate O-ring behavior. Seventy tests using PCV mock-ups were assembled and heated to temperatures ranging from 200 to 450 ºF. They were leak-tested initially and have been tested periodically to determine if they continue to meet the leak-tightness criterion defined in ANSI standard N14.5-97. Due to material substitution, fourteen additional tests were initiated in 2008 with GLT-S O-rings heated to temperatures ranging from 200 to 400 ºF. High temperature aging continues for 23 GLT O-ring fixtures at 200 – 270 ºF. Room temperature leak test failures have been experienced in all of the GLT O-ring fixtures aging at 350 ºF and higher temperatures, and in 8 fixtures aging at 300 ºF. The earliest 300 °F GLT Oring fixture failure was observed at 34 months. The remaining GLT O-ring fixtures aging at 300 ºF have been retired from testing following more than 5 years at temperature without failure. No failures have yet been observed in GLT O-ring fixtures aging at 200 ºF for 84 - 108 months, which bounds O-ring temperatures anticipated during storage in K-Area Complex (KAC). Based on expectations that the 200 ºF fixtures will remain leak-tight for a significant period yet to come, 2 additional fixtures began aging in 2011 at 270 ºF, with hopes that they may reach a failure condition before the 200 ºF fixtures, thus providing additional time to failure data. High temperature aging continues for 5 GLT-S O-ring fixtures at 200 – 300 ºF. Room temperature leak test failures have been experienced in all 8 of the GLT-S O-ring fixtures aging at 350 and 400 ºF, and in one GLT-S O-ring fixture aging at 300 ºF. No failures have yet been observed in GLT-S O-ring fixtures aging at 200 - 250 ºF for 66 months. One O-ring fixture has failed since the last interim report was issued. Both O-rings in one GLTS fixture aging at 300 ºF failed to remain leak-tight after 69 months at temperature. Aging and periodic leak testing will continue for the remaining PCV fixtures. Additional irradiation of several fixtures has been performed in the last year to maintain a balance between thermal and radiation exposures similar to that experienced in storage, and to show the degree of consistency of radiation response between GLT and GLT-S O-rings.

42 ENGINEERING↗

DOE OSTI2015

An Analysis of Representative Heating Load Lines for Residential HSPF Ratings

This report describes an analysis to investigate representative heating loads for single-family detached homes using current EnergyPlus simulations (DOE 2014a). Hourly delivered load results are used to determine binned load lines using US Department of Energy (DOE) residential prototype building models (DOE 2014b) developed by Pacific Northwest National Laboratory (PNNL). The selected residential single-family prototype buildings are based on the 2006 International Energy Conservation Code (IECC 2006) in the DOE climate regions. The resulting load lines are compared with the American National Standards Institute (ANSI)/Air-Conditioning, Heating, and Refrigeration Institute (AHRI) Standard 210/240 (AHRI 2008) minimum and maximum design heating requirement (DHR) load lines of the heating seasonal performance factor (HSPF) ratings procedure for each region. The results indicate that a heating load line closer to the maximum DHR load line, and with a lower zero load ambient temperature, is more representative of heating loads predicted for EnergyPlus prototype residential buildings than the minimum DHR load line presently used to determine HSPF ratings. An alternative heating load line equation was developed and compared to binned load lines obtained from the EnergyPlus simulation results. The effect on HSPF of the alternative heating load line was evaluated for single-speed and two-capacity heat pumps, and an average HSPF reduction of 16% was found. The alternative heating load line relationship is tied to the rated cooling capacity of the heat pump based on EnergyPlus autosizing, which is more representative of the house load characteristics than the rated heating capacity. The alternative heating load line equation was found to be independent of climate for the six DOE climate regions investigated, provided an adjustable zero load ambient temperature is used. For Region IV, the default DOE climate region used for HSPF ratings, the higher load line results in an ~28% increase in delivered heating load and an ~52% increase in the estimated heating operating cost over that given in the AHRI directory (AHRI 2014).

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2015

Stationary Liquid Fuel Fast Reactor

For effective burning of hazardous transuranic (TRU) elements of used nuclear fuel, a transformational advanced reactor concept named SLFFR (Stationary Liquid Fuel Fast Reactor) was proposed based on stationary molten metallic fuel. The fuel enters the reactor vessel in a solid form, and then it is heated to molten temperature in a small melting heater. The fuel is contained within a closed, thick container with penetrating coolant channels, and thus it is not mixed with coolant nor flow through the primary heat transfer circuit. The makeup fuel is semi- continuously added to the system, and thus a very small excess reactivity is required. Gaseous fission products are also removed continuously, and a fraction of the fuel is periodically drawn off from the fuel container to a processing facility where non-gaseous mixed fission products and other impurities are removed and then the cleaned fuel is recycled into the fuel container. A reference core design and a preliminary plant system design of a 1000 MWt TRU- burning SLFFR concept were developed using TRU-Ce-Co fuel, Ta-10W fuel container, and sodium coolant. Conservative design approaches were adopted to stay within the current material performance database. Detailed neutronics and thermal-fluidic analyses were performed to develop a reference core design. Region-dependent 33-group cross sections were generated based on the ENDF/B-VII.0 data using the MC2-3 code. Core and fuel cycle analyses were performed in theta-r-z geometries using the DIF3D and REBUS-3 codes. Reactivity coefficients and kinetics parameters were calculated using the VARI3D perturbation theory code. Thermo-fluidic analyses were performed using the ANSYS FLUENT computational fluid dynamics (CFD) code. Figure 0.1 shows a schematic radial layout of the reference 1000 MWt SLFFR core, and Table 0.1 summarizes the main design parameters of SLFFR-1000 loop plant. The fuel container is a 2.5 cm thick cylinder with an inner radius of 87.5 cm. The fuel container is penetrated by twelve hexagonal control assembly (CA) guide tubes, each of which has 3.0 mm thickness and 69.4 mm flat-to-flat outer distance. The distance between two neighboring CA guide tube is selected to be 26 cm to provide an adequate space for CA driving systems. The fuel container has 18181 penetrating coolant tubes of 6.0 mm inner diameter and 2.0 mm thickness. The coolant tubes are arranged in a triangular lattice with a lattice pitch of 1.21 cm. The fuel, structure, and coolant volume fractions inside the fuel container are 0.386, 0.383, and 0.231, respectively. Separate steel reflectors and B4C shields are used outside of the fuel container. Six gas expansion modules (GEMs) of 5.0 cm thickness are introduced in the radial reflector region. Between the radial reflector and the fuel container is a 2.5 cm sodium gap. The TRU inventory at the beginning of equilibrium cycle (BOEC) is 5081 kg, whereas the TRU inventory at the beginning of life (BOL) was 3541 kg. This is because the equilibrium cycle fuel contains a significantly smaller fissile fraction than the LWR TRU feed. The fuel inventory at BOEC is composed of 34.0 a/o TRU, 41.4 a/o Ce, 23.6 a/o Co, and 1.03 a/o solid fission products. Since uranium-free fuel is used, a theoretical maximum TRU consumption rate of 1.011 kg/day is achieved. The semi-continuous fuel cycle based on the 300-batch, 1- day cycle approximation yields a burnup reactivity loss of 26 pcm/day, and requires a daily reprocessing of 32.5 kg of SLFFR fuel. This yields a daily TRU charge rate of 17.45 kg, including a makeup TRU feed of 1.011 kg recovered from the LWR used fuel. The charged TRU-Ce-Co fuel is composed of 34.4 a/o TRU, 40.6 a/o Ce, and 25.0 a/o Co.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2015

Pressure distribution along the AGS vacuum chambers with new types of pump out conduits

The AGS HEBT and ring vacuum system is monitored by the discharge current of the magnet ion pumps, which is proportional to the pressure at the inlet port of these ion pumps. The discharge current is measured and suitably calibrated to indicate the ion pump pressure. In order to calculate the vacuum chamber pressure from the ion pump pressure, a detailed analysis is essential to compute their difference in different scenarios. Such analysis has been carried out numerically in the past for the system with the older type of pump out conduits, and similar analysis using FEM in ANSYS is presented in this paper with the newer type of pump out conduit.

43 PARTICLE ACCELERATORS↗

DOE OSTI2015

Analysis of Precipitation (Rain and Snow) Levels and Straight-line Wind Speeds in Support of the 10-year Natural Phenomena Hazards Review for Los Alamos National Laboratory

This report provides site-specific return level analyses for rain, snow, and straight-line wind extreme events. These analyses are in support of the 10-year review plan for the assessment of meteorological natural phenomena hazards at Los Alamos National Laboratory (LANL). These analyses follow guidance from Department of Energy, DOE Standard, Natural Phenomena Hazards Analysis and Design Criteria for DOE Facilities (DOE-STD-1020-2012), Nuclear Regulatory Commission Standard Review Plan (NUREG-0800, 2007) and ANSI/ ANS-2.3-2011, Estimating Tornado, Hurricane, and Extreme Straight-Line Wind Characteristics at Nuclear Facility Sites. LANL precipitation and snow level data have been collected since 1910, although not all years are complete. In this report the results from the more recent data (1990–2014) are compared to those of past analyses and a 2004 National Oceanographic and Atmospheric Administration report. Given the many differences in the data sets used in these different analyses, the lack of statistically significant differences in return level estimates increases confidence in the data and in the modeling and analysis approach.

58 GEOSCIENCES↗

DOE OSTI2015

Decontaminant delivery and application methods to enhance decontamination process and efficacy

The objective for the experimental effort was to provide validation for the electrostatic aerosol transport models for particle size and deposition rate and to determine the feasibility of an electrostatic spray process in delivering non-corrosive decontaminants to complex interior spaces, such as an aircraft. The project utilized ITW (Illinois Tool Works) rotary atomizing induction charged nozzle to disperse small, charged droplets of liquid decontaminants uniformly through a contaminated space. Particle size and deposition studies were conducted prior to the feasibility study where the ITW nozzle was optimized and characterized for two decontaminants: EasyDeconTM200 (DF-200) and Steriplex® SD. In addition to the validation studies, two feasibility studies were conducted with anthrax simulant (B. atrophaeus) and sarin simulant (diphenol chlorophosphate, DPCP). Running parameters for the two studies varied according to the starting contaminant challenges (1.0 x 108 CFU/m 2 for B. atrophaeus and 1.0 g/m 2 for DPCP), the amount of decontaminant deposition, and, finally, decontaminant to agent contact time. Results for the DPCP study confirm that our spray method met and exceeded the threshold criteria of <10 mg/m 2 , postdecontamination, for Teflon and aluminum coupons. Results from this study also showed that polycarbonate and rubber coupons can be reduced by <98% and <92%, respectively. Results for the B. atrophaeus study presented a slightly different challenge due to coupon size, however, increasing the size of the coupon confirmed that it is possible for our spray method to meet the threshold criteria of <100 CFU/m 2 . In addition, a computational model was developed in ANSYS Fluent to solve for the air flow, space charge, electric field, and droplet motion involved in electrostatic aerosol transport. Comparison of the model to experiments resulted in good agreement in deposition pattern and total mass deposited on surfaces. Finally, as a consequence of this project, the methodology used for decontamination could be used to improve future contamination scenarios by eliminating or reducing contaminant hazards, thereby allowing equipment and/or facilities, previously unusable, to be reclaimed rather than discarded, resulting in an overall cost savings to the customer.

36 MATERIALS SCIENCE↗

DOE OSTI2016

Verification of Advective Bar Elements Implemented in the Aria Thermal Response Code.

A verification effort was undertaken to evaluate the implementation of the new advective bar capability in the Aria thermal response code. Several approaches to the verification process were taken : a mesh refinement study to demonstrate solution convergence in the fluid and the solid, visually examining the mapping of the advective bar element nodes to the surrounding surfaces, and a comparison of solutions produced using the advective bars for simple geometries with solutions from commercial CFD software . The mesh refinement study has shown solution convergence for simple pipe flow in both temperature and velocity . Guidelines were provided to achieve appropriate meshes between the advective bar elements and the surrounding volume. Simulations of pipe flow using advective bars elements in Aria have been compared to simulations using the commercial CFD software ANSYS Fluent (r) and provided comparable solutions in temperature and velocity supporting proper implementation of the new capability. Verification of Advective Bar Elements iv Acknowledgements A special thanks goes to Dean Dobranich for his guidance and expertise through all stages of this effort . His advice and feedback was instrumental to its completion. Thanks also goes to Sam Subia and Tolu Okusanya for helping to plan many of the verification activities performed in this document. Thank you to Sam, Justin Lamb and Victor Brunini for their assistance in resolving issues encountered with running the advective bar element model. Finally, thanks goes to Dean, Sam, and Adam Hetzler for reviewing the document and providing very valuable comments.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2016

JacketSE: An Offshore Wind Turbine Jacket Sizing Tool; Theory Manual and Sample Usage with Preliminary Validation

This manual summarizes the theory and preliminary verifications of the JacketSE module, which is an offshore jacket sizing tool that is part of the Wind-Plant Integrated System Design & Engineering Model toolbox. JacketSE is based on a finite-element formulation and on user-prescribed inputs and design standards' criteria (constraints). The physics are highly simplified, with a primary focus on satisfying ultimate limit states and modal performance requirements. Preliminary validation work included comparing industry data and verification against ANSYS, a commercial finite-element analysis package. The results are encouraging, and future improvements to the code are recommended in this manual.

17 WIND ENERGY↗

DOE OSTI2016

Airside HVAC BESTEST. Adaptation of ASHRAE RP 865 Airside HVAC Equipment Modeling Test Cases for ASHRAE Standard 140. Volume 1, Cases AE101-AE445

This report documents a set of diagnostic analytical verification cases for testing the ability of whole building simulation software to model the air distribution side of typical heating, ventilating and air conditioning (HVAC) equipment. These cases complement the unitary equipment cases included in American National Standards Institute (ANSI)/American Society of Heating, Refrigerating, and Air-Conditioning Engineers (ASHRAE) Standard 140, Standard Method of Test for the Evaluation of Building Energy Analysis Computer Programs, which test the ability to model the heat-transfer fluid side of HVAC equipment.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2014

CFD Simulations of a Regenerative Process for Carbon Dioxide Capture in Advanced Gasification Based Power Systems

This project describes the work carried out to prepare a highly reactive and mechanically strong MgO based sorbents and to develop a Population Balance Equations (PBE) approach to describe the evolution of the particle porosity distribution that is linked with Computational Fluid Dynamics (CFD) to perform simulations of the CO2 capture and sorbent regeneration. A large number of MgO-based regenerable sorbents were prepared using low cost and abundant dolomite as the base material. Among various preparation parameters investigated the potassium/magnesium (K/Mg) ratio was identified as the key variable affecting the reactivity and CO2 capacity of the sorbent. The optimum K/Mg ratio is about 0.15. The sorbent formulation HD52-P2 was identified as the “best” sorbent formulation and a large batch (one kg) of the sorbent was prepared for the detailed study. The results of parametric study indicate the optimum carbonation and regeneration temperatures are 360° and 500°C, respectively. The results also indicate that steam has a beneficial effect on the rate of carbonation and regeneration of the sorbent and that the reactivity and capacity of the sorbent decreases in the cycling process (sorbent deactivation). The results indicate that to achieve a high CO2 removal efficiency, the bed of sorbent should be operated at a temperature range of 370-410°C which also favors production of hydrogen through the WGS reaction. To describe the carbonation reaction kinetics of the MgO, the Variable Diffusivity shrinking core Model (VDM) was developed in this project, which was shown to accurately fit the experimental data. An important advantage of this model is that the changes in the sorbent conversion with time can be expressed in an explicit manner, which will significantly reduce the CFD computation time. A Computational Fluid Dynamic/Population Balance Equations (CFD/PBE) model was developed that accounts for the particle (sorbent) porosity distribution and a new version of the method of moments, called Finite size domain Complete set of trial functions Method Of Moments (FCMOM) was used to solve the population balance equations. The PBE model was implemented in a commercial CFD code, Ansys Fluent 13.0. The code was used to test the model in some simple cases and the results were verified against available analytical solution in the literature. Furthermore, the code was used to simulate CO2 capture in a packed-bed and the results were in excellent agreement with the experimental data obtained in the packed bed. The National Energy Laboratory (NETL) Carbon Capture Unit (C2U) design was used in simulate of the hydrodynamics of the cold flow gas/solid system (Clark et al.58). The results indicate that the pressure drop predicted by the model is in good agreement with the experimental data. Furthermore, the model was shown to be able to predict chugging behavior, which was observed during the experiment. The model was used as a base-case for simulations of reactive flow at elevated pressure and temperatures. The results indicate that by controlling the solid circulation rate, up to 70% CO2 removal can be achieved and that the solid hold up in the riser is one of the main factors controlling the extent of CO2 removal. The CFD/PBE simulation model indicates that by using a simulated syngas with a composition of 20% CO2, 20% H2O, 30% CO, and 30% H2, the composition (wet basis) in the reactor outlet corresponded to about 60% CO2 capture with and exit gas containing 65% H2. A preliminary base-case-design was developed for a regenerative MgO-based pre-combustion carbon capture process for a 500 MW IGCC power plant. To minimize the external energy requirement, an extensive heat integration network was developed in Aspen/HYSYS® to produce the steam required in the regenerator and heat integration. In this process, liquid CO2 produced at 50 atm can easily be pumped and sequestered or stored. The preliminary economic analyses indicate that the estimated cost of carbon v capture is in the range of $31-$44/ton, suggesting that a regenerative MgO-Based process can be a viable option for pre-combustion carbon dioxide capture in advanced gasification based power systems.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2016

Eleventh interim status report: Model 9975 O-Ring fixture long-term leak performance

42 ENGINEERING↗

DOE OSTI2014

SERIIUS-MAGEEP Visiting Scholars Program

Recent studies have assessed closed-loop supercritical carbon dioxide (s-CO 2 ) Brayton cycles to be a higher energy-density system in comparison to equivalent superheated steam Rankine systems. At turbine inlet conditions of 700°C and 20 MPa, a cycle thermal efficiency of ~50% can be achieved. Achieving these high efficiencies will help concentrating solar power (CSP) technologies to become a competitive alternative to current power generation methods. To incorporate an s-CO 2 Brayton power cycle in a solar power tower system, the development of a solar receiver capable of providing an outlet temperature of 700°C (at 20 MPa) is necessary. To satisfy the temperature requirements of an s-CO 2 Brayton cycle with recuperation and recompression, the s-CO 2 must undergo a temperature rise of ~200°C as it flows through the solar receiver. The main objective is to develop an optical-thermal-fluid and structural model to validate a tubular receiver that will receive a heat input ~0.33 MWth from the heliostat field at the National Solar Thermal Test Facility (NSTTF), Albuquerque, NM, USA. We also commenced the development of computational models and testing of air receivers being developed by the Indian Institute of Science (IISc) and the Indian Institute of Technology in Bombay (IIT-B). The helical tubular receiver is expected to counteract the effect of thermal expansion while using a cavity to reduce the radiative and convective losses. Initially, this receiver will be tested for a temperature range of 100-300°C under 1 MPa of pressurized air. The helical air receiver will be exposed to 10kWth to achieve a temperature rise of ~200°C. Preliminary tests to validate the modeling will be performed before the design and construction of a larger scale receiver. Lastly, I focused on the development of a new computational tool that would allow us to perform a nodal creep-fatigue analysis on the receivers and heat exchangers being developed. This tool was developed using MATLAB and is capable of processing the results obtained from ANSYS Fluent and Structural combined, which was limited when using commercial software. The main advantage of this code is that it can be modified to run in parallel making it more affordable and faster compared to commercial codes available. The code is in the process of validation and is currently being compared to nCode Design Life.

25 ENERGY STORAGE↗

DOE OSTI2016

Preparation and testing of corrosion and spallation-resistant coatings

The goal of this project was to take a recently developed method of bonding oxide dispersion-strengthened (ODS) FeCrAl plating to nickel superalloys closer to commercial use in syngas-fired turbines. The project was designed to better understand and develop the bonding process and to determine if plating APMT®, a specific highly oxidation-resistant ODS FeCrAl alloy made by Kanthal, onto nickel-based superalloy turbine parts is a viable method for substantially improving the lifetimes and maximum use temperatures of the parts. The superalloys investigated for protection were CM247LC and Rene® 80, both alumina scale-forming alloys. The method for bonding the APMT plate to the superalloys is called evaporative metal bonding, which involves placing a thin foil of zinc between the plate and the superalloy, clamping them together, and heating in an atmosphere-controlled furnace. Upon heating, the zinc melts and dissolves the oxide skins of the alloys at the bond line, allowing the two alloys to diffuse into each other. The zinc then diffuses through the alloys and evaporates from their surfaces, creating a bond between the APMT and the superalloy that is stronger than the APMT itself. Testing showed that the diffusivity of zinc in both APMT and CM247LC is quite similar at 700°C but 15 times higher in the APMT at 1214°C. Coefficients of thermal expansion were determined for each of the alloys as a function of temperature. This information was entered into a finite-element model using ANSYS, which was used to design a clamping jig for pressing the APMT to the superalloys at the bonding temperature. Scanning electron microscopy analyses of representative joints showed that no zinc remained in the alloys after bonding Unfortunately, the analyses also showed some small pieces of broken aluminum oxide scale near the bond lines, indicating that its scale was not sufficiently removed during prebonding cleaning. Samples from each of the bonded blocks were sent to Siemens for its standard oxidation, spallation, and corrosion testing, which was scheduled for completion in the spring of 2016. However, because of commercial demands, the tests were not completed by the time of this report except some initial spallation tests at 1150°C. In those tests, several of the APMT plates separated from the CM247LC, likely because of the remaining aluminum oxide scale on the surface of the CM247LC. This implies that surface preparation may need to include machining to remove the oxide scale before bonding rather than just sandblasting. In previous tensile testing at 950°C, the breaks in the tensile samples always occurred in the APMT and not at the joints. Gasifier sampling was completed to determine what types of trace contaminants may occur in cleaned and combusted syngas and that could lead to corrosion or deposition in turbines firing coal syngas. The sampling was done from a pressurized fluidized-bed gasifier and a pressurized entrained-flow gasifier. The particles captured on a filter from syngas were typically 0.2 to 0.5 μm in diameter, whereas those captured from the combusted syngas were slightly larger and more spherical. X-ray photoelectron spectroscopy done at Oak Ridge National Laboratory showed that the particles do not contain any metals and have an atomic composition almost identical to that of the polycarbonate filter. This indicates that the particles are primarily soot-based and not formed from volatilization of metals in the gasifiers.

20 FOSSIL-FUELED POWER PLANTS↗