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DOE OSTI2025

Characterization of Fuel-to-Coolant Heat Transfer During Reactivity-Initiated Accidents Using Tightly Coupled Thermal Hydraulics and Fuel Thermomechanics

The reactivity-initiated accident (RIA) is a complex scenario with several tightly interacting physical phenomena. Accurately predicting fuel behavior during these transients is difficult due to limitations in the modeling of fuel-to-coolant heat transfer. Common approaches to simulate RIAs involve standalone calculations using either a fuel performance code or a thermal-hydraulic code. The complex interdependencies of thermal-hydraulic and fuel mechanical behavior suggest that a tight coupling between these codes may provide more accurate predictions of fuel-to-coolant heat transfer and cladding mechanical response. Here, RELAP5-3D and BISON are coupled in this paper to simulate RIAs, and a sensitivity analysis is performed to rank key thermal properties and two-phase heat transfer parameters relevant for fuel-to-coolant heat transfer and cladding failure mechanisms in UO 2 –Zircaloy-4 systems. Gas gap conductance, film boiling heat transfer uncertainty, pulse width, fuel-specific heat capacity, and cladding-specific heat capacity were identified as important parameters. Variations in figures of merit resulting from changes to pulse width and the material thermal properties indicate that time-dependent heat transfer rates are significant for safety-relevant mechanical parameters due to the time dependence of cladding ductility and pellet-cladding mechanical interaction loading. The results suggest that the thermal-hydraulic factors have a nonnegligible influence on the thermomechanical solution and vice versa. Tight coupling of both sets of physics is recommended to improve prediction of fuel behavior during RIAs. Highlights include the following: 1. The RELAP5-3D thermal-hydraulic code and the BISON fuel performance code are tightly coupled for simulation of RIA transients with energy depositions at the Zircaloy-4 cladding failure threshold. 2. Departure from nucleate boiling occurred for all simulated cases. Due to the ductility of fresh fuel, substantial ballooning occurred in most cases. 3. Gas gap conductance, fuel-specific heat capacity, cladding-specific heat capacity, transient pulse width, and film boiling heat transfer were the dominant thermal factors impacting the safety figures of merit at energy depositions.

Critical Heat Flux (CHF)↗

DOE OSTI2022

Evaluation of Performance Variables to Accelerate the Deployment of Sustainable Aviation Fuels at a Regional Scale

An increase in jet fuel consumption and its associated emissions across the world have led to the need for alternative technologies to produce sustainable aviation fuels (SAF). One option to produce SAFs is to utilize waste or biomass-based feedstocks that has the potential to reduce greenhouse gas emissions by 50% or more compared to conventional jet fuel. However, there is a lack of understanding of how the synergistic effects of key performance variables could hinder or help the deployment of aviation fuels on a regional scale. Here, we assess the implications of key variables-including type and quantity of waste/biomass feedstock availability near the airport, cost of SAF production, life cycle greenhouse gas (GHG) emissions, policies, and fuel/infrastructure logistics-on the deployment of SAF at Chicago's O'Hare International Airport. We consider three ASTM International-approved SAF technologies (Hydroprocessed Esters and Fatty Acids, Fischer-Tropsch, and Alcohol to Jet) that can be blended up to 50% with petroleum-based jet fuel. Results from our analysis show that woody biomass-based Fischer-Tropsch technology has the lowest fuel production costs ($2.31-$2.81/gallon gasoline equivalent) of all pathways, and it reduces life cycle GHG emissions by 86% compared to conventional jet fuel despite the higher availability of crop residues compared to either woody biomass or fats, oils, and greases. Also, infrastructure is available at O'Hare International Airport to blend SAF with Jet A fuel through three terminals directly connected to the airport via pipelines. Our sensitivity analysis shows renewable fuel incentives and feedstock price to be key performance variables affecting the production cost and deployment of SAF.

alcohol-to-jet↗

DOE OSTI2017

Hydrogen Safety Sensor Performance and Use Gap Analysis: Preprint

Hydrogen sensors are recognized as an important technology for facilitating the safe implementation of hydrogen as an alternative fuel, and there are numerous reports of a sensor alarm successfully preventing a potentially serious event. However, gaps in sensor metrological specifications, as well as in their performance for some applications, exist.The U.S. Department of Energy (DOE) Fuel Cell Technology Office published a short list of critical gaps in the 2007 and 2012 multiyear project plans; more detailed gap analyses were independently performed by the JRC and NREL. There have been, however, some significant advances in sensor technologies since these assessments, including the commercial availability of hydrogen sensors with fast response times (t90 less than 1 s, which had been an elusive DOE target since 2007), improved robustness to chemical poisons, improved selectivity, and improved lifetime and stability. These improvements, however, have not been universal and typically pertain to select platforms or models. Moreover, as hydrogen markets grow and new applications are being explored, more demands will be imposed on sensor performance. The hydrogen sensor laboratories at NREL and JRC are currently updating the hydrogen safety sensor gap analysis through direct interaction with international stakeholders in the hydrogen community, especially end-users. NREL and the JRC are currently organizing a series of workshops (in Europe and the U.S.) with sensor developers, end-users, and other stakeholders in 2017 to identify technology gaps and to develop a path forward to address them. One workshop is scheduled for May 10 in Brussels, Belgium at the Headquarters of the Fuel Cell and Hydrogen Joint Undertaking. A second workshop is planned at the National Renewable Energy Laboratory in Golden, CO, USA. This presentation will review improvements in sensor technologies in the past 5 to 10 years, identify gaps in sensor performance and use requirements, and identify potential research strategies to address the gaps. The presentation will also summarize the outcomes of the Hydrogen Sensors Workshops.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2018

Establishing a neutronics design and equilibrium cycle analysis for the I 2 S-LWR reactor with UO 2 and U 3 Si 2 Fuel

The Integral Inherently Safe (I 2 S-LWR) reactor was developed not only to enhance passive reactor safety performance, but also to improve reactor economics. This paper describes the steady-state and depletion analysis of the I 2 S-LWR core using both UO 2 and U 3 Si 2 fuel designs. The development and validation of the core models are described, to include the generation of HELIOS cross sections and comparison with the WEC lattice code PARAGON and the Monte Carlo code SERPENT. The few group homogenized cross sections were then prepared for the U.S. NRC PARCS core simulator using the GenPMAXS code. The multicycle capability in PARCS was used to determine the equilibrium core condition for three batch cores loaded with the UO 2 and then with the U 3 Si 2 fuel designs. Comparing the results from the WEC code ANC at beginning, middle, and end of cycle showed good agreement. Core conditions at beginning and end of cycle were then used to determine the converged steady-state conditions of a coupled RELAP5/PARCS model, which provided the initial condition for various transient accident simulations which are reported in a companion paper.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

NASA NTRS2005

Solid Oxide Fuel Cell/Gas Turbine Hybrid Cycle Technology for Auxiliary Aerospace Power

A notional 440 kW auxiliary power unit has been developed for 300 passenger commercial transport aircraft in 2015AD. A hybrid engine using solid-oxide fuel cell stacks and a gas turbine bottoming cycle has been considered. Steady-state performance analysis during cruise operation has been presented. Trades between performance efficiency and system mass were conducted with system specific energy as the discriminator. Fuel cell performance was examined with an area specific resistance. The ratio of fuel cell versus turbine power was explored through variable fuel utilization. Area specific resistance, fuel utilization, and mission length had interacting effects upon system specific energy. During cruise operation, the simple cycle fuel cell/gas turbine hybrid was not able to outperform current turbine-driven generators for system specific energy, despite a significant improvement in system efficiency. This was due in part to the increased mass of the hybrid engine, and the increased water flow required for on-board fuel reformation. Two planar, anode-supported cell design concepts were considered. Designs that seek to minimize the metallic interconnect layer mass were seen to have a large effect upon the system mass estimates.

Steffen, Christopher J., Jr.↗

DOE OSTI2017

Analysis of hydrogen as a Transportation Fuel FY17 Report

This report summarizes the results of literature reviews, surveys and analyses performed to evaluate the potential of hydrogen-fueled vehicles to be an economically viable transportation alternative. Five existing and important drivers of expanding hydrogen-fueled transportation adoption are multi-billion dollar sales reservations of Nikola Class 8 trucks, CALSTART viability analysis of hybrid-hydrogen drayage trucks in the shipyard cargo application, analysis showing economic advantages of Fuel Cell Electric Vehicles (FCEV)s over Battery Electric Vehicles (BEV)s beginning at 150-mile ranges, the announcement of a commercial 5kg electrolyzer, and commercial plans or vehicle availability by nine vehicle manufacturers of FCEV passenger vehicles. But hydrogen infrastructure availability needed to support broad adoption of hydrogen-fueled vehicles is limited to less than 50 publicly-available refueling stations, primarily in California. The demand side (consumer) economics associated with FCEV adoption showed strong economic sensitivity to the original vehicle’s fuel economy (mpg), distance traveled, and hydrogen (H2) generation costs. Seven use cases were used to evaluate the broad range of potential FCEV purchasers, including autonomous vehicle applications. Each consumer use case analysis resulted in a different hydrogen fuel cost that would be equivalent to the current fuel cost being paid by the consumer. The H2 generation costs (supply side) were sensitive to the volume of H2 supplied and H2 production costs needed to repay H2 supply facility capital costs and produce competitively-priced energy. H2FAST was used to more accurately incorporate capital, maintenance and production costs into a viable H2 supply cost to the consumer. When the H2 generation and consumer economics were combined, several applications with positive economics became clear. The availability of low-cost hydrogen pipeline connections, and therefore low-cost hydrogen, greatly benefits the California drayage truck application with hybrid-hydrogen retrofits being repaid within seven years. Class 8 trucks could also take advantage of these low-cost, but regional hydrogen supplies. In addition, the IVYS electrolyzer-based hydrogen generation product showed the potential to deliver hydrogen economically in an urban or freeway off-ramp setting to a limited number of passenger vehicles in areas with low-cost electricity. These positive, manually developed results show the need to develop more advanced tools to provide an expanded evaluation of the economics of hydrogen-based fuel applications. The use cases evaluated showed significant potential for hydrogen-fueled vehicles to have a sustainable impact as a transportation fuel. The positive impact is not limited to transportation fuels, but also grid resilience and flexibility through the use of controllable and variable electrolyzer output to rapidly adjust to changing grid conditions and enable greater integration of solar and wind generated power. This capability would directly enable alternative fuel vehicles to impact energy consumption, GHG emissions, and the economy at the regional and national levels.

08 HYDROGEN↗

DOE OSTI2020

Transition Core Analysis for HEU to LEU Fuel Conversion at the University of Missouri Research Reactor

A new type of low-enriched uranium (LEU) fuel based on an alloy of uranium and molybdenum is expected to allow the conversion of U.S. domestic high-performance research and test reactors requiring high density fuel from highly enriched uranium (HEU) to LEU. The University of Missouri Research Reactor (MURR (R)) has undergone design and performance calculations for conversion to this LEU fuel. Presented in this paper is the analysis of a crucial step in the conversion process: the sequence of MURR transition cores from all fresh to equilibrium burnup LEU operations. During the initial conversion from HEU to LEU fuel, MURR will operate atypically due to the lack of burned LEU elements. Given the constraints of MURR operation and experiments, a proposed transition scheme minimizes the time MURR operates atypically compared to the prototypic cycles currently run with HEU fuel and moves quickly to the same sort of equilibrium cycles for the LEU fuel.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2019

Fuel Cell Electric Vehicle Durability and Fuel Cell Performance

The objectives of this project are to validate hydrogen fuel cell electric vehicles (FCEVs) in real-world settings and to identify the current status and evolution of the technology. The analysis objectively assesses progress toward targets and market needs defined by the U.S. Department of Energy and stakeholders, provides feedback to hydrogen research and development, and publishes results for key stakeholder use and investment decisions. Fiscal year 2018 objectives focus on analysis and reporting of FCEV driving range, fuel economy, drive and fill behaviors, durability, fill performance, and fuel cell performance. This report specifically addresses the topics of fuel cell stack durability and fuel cell performance.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2025

High Flux Isotope Reactor Low-Enriched Uranium High Density Silicide Fuel Preliminary Design Update: System Transient Analysis

As a part of conversion efforts from highly enriched uranium (HEU) to low-enriched uranium (LEU) fuel under direction of the National Nuclear Security Administration of the U.S. Department of Energy, multiple proposed designs of the High Flux Isotope Reactor (HFIR) have been created and assessed regarding reactor physics performance metrics, including designs utilizing uranium silicide dispersion fuel (U3Si2-Al). This report updates the previous analyses that evaluated the nuclear safety performance of LEU fuel designs with respect to selected accident events from the HFIR Safety Analysis Report (SAR). Both the Low Density (LD) and High Density (HD) Optimized designs’ reactivity initiated accident fuel performance improved relative to the HEU fuel, attributed to greater 238 U negative Doppler feedback. However, the thermal margins for primary coolant system accidents were reduced with some acceptance criteria unable to be met. The need to resolve reduced thermal margin, open modeling items, and unresolved assumptions was identified.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

Advanced Modular Sub-Atmospheric Hybrid Heat Engine (Phase 1 Final Report)

The Phase 1 Final Report describes the results of the work completed during the “Advanced Modular Sub-Atmospheric Hybrid Heat Engine” project. The objectives of Phase 1 work were to develop a conceptual design of the turbine-based modular hybrid heat engine (MHHE), including thermodynamic cycle analysis, define the nominal engine component boundary conditions, identify technology gaps, and develop a detailed test plan to address these gaps through bench scale testing in a potential subsequent Phase 2 project. To achieve the project objective, the following activities were performed in Phase 1 work: (1) Market analysis and primary fuel selection, (2) Conceptual design and integrated layout development, (3) Design support and key components characterization, (4) Planning to move technology to pre-commercial demonstration.

42 ENGINEERING↗

NASA NTRS1932

Compression-ignition engine tests of several fuels

The tests reported in this paper were made to devise simple engine tests which would rate fuels as to their comparative value and their suitability for the operating conditions of the individual engine on which the tests are made. Three commercial fuels were used in two test engines having combustion chambers with and without effective air flow. Strictly comparative performance tests gave almost identical results for the three fuels. Analysis of indicator cards allowed a differentiation between fuels on a basis of rates of combustion. The same comparative ratings were obtained by determining the consistent operating range of injection advance angle for the three fuels. The difference in fuels is more pronounced in a quiescent combustion chamber than in one with high-velocity air flow. A fuel is considered suitable for the operating conditions of an engine with a quiescent combustion chamber if it permits the injection of the fuel to be advanced beyond the optimum without exceeding allowable knock or allowable maximum cylinder pressures.

Spanogle, J A↗

DOE OSTI2025

Serpent - Bison - THM Preliminary Multiphysics Modeling of a Nuclear Thermal Propulsion System Fuel Assembly

This work demonstrates the Monte Carlo neutronic and Thermo-Hydraulic coupling scheme using the Serpent code and MOOSE application Bison and Thermo Hydraulic Module. The coupling scheme is then applied to the reference BWX Technologies Nuclear Ther- mal Propulsion system at he fuel assembly level where it’s used to perform an analysis of the isothermal material coefficients and potential material reactivity worth. A method is developed to isolate which feedback effects should be considered for proceeding with reduced order deterministic neutronic modeling where branch off analysis must be con- ducted. The convergence behavior of the coupling scheme is demonstrated where it fol- lows the standard Picard iteration approach. Verification studies for the method of deduc- ing relevant feedback effects is also demonstrated.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2013

A new approach for modeling and analysis of molten salt reactors using SCALE

The Office of Fuel Cycle Technologies (FCT) of the DOE Office of Nuclear Energy is performing an evaluation and screening of potential fuel cycle options to provide information that can support future research and development decisions based on the more promising fuel cycle options. [1] A comprehensive set of fuel cycle options are put into evaluation groups based on physics and fuel cycle characteristics. Representative options for each group are then evaluated to provide the quantitative information needed to support the valuation of criteria and metrics used for the study. Included in this set of representative options are Molten Salt Reactors (MSRs), the analysis of which requires several capabilities that are not adequately supported by the current version of SCALE or other neutronics depletion software packages (e.g., continuous online feed and removal of materials). A new analysis approach was developed for MSR analysis using SCALE by taking user-specified MSR parameters and performing a series of SCALE/TRITON calculations to determine the resulting equilibrium operating conditions. This paper provides a detailed description of the new analysis approach, including the modeling equations and radiation transport models used. Results for an MSR fuel cycle option of interest are also provided to demonstrate the application to a relevant problem. The current implementation is through a utility code that uses the two-dimensional (2D) TRITON depletion sequence in SCALE 6.1 but could be readily adapted to three-dimensional (3D) TRITON depletion sequences or other versions of SCALE. (authors)

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

NASA NTRS2000

Raman Gas Species Measurements in Hydrocarbon-Fueled Rocket Engine Injector Flows

Propellent injector development at MSFC (Marshall Space Flight Center) includes experimental analysis using optical techniques, such as Raman, fluorescence, or Mie scattering. For the application of spontaneous Raman scattering to hydrocarbon-fueled flows a technique needs to be developed to remove the interfering polycyclic aromatic hydrocarbon fluorescence from the relatively weak Raman signals. A current application of such a technique is to the analysis of the mixing and combustion performance of multijet, impinging-jet candidate fuel injectors for the baseline Mars ascent engine, which will burn methane and liquid oxygen produced in-situ on Mars to reduce the propellent mass transported to Mars for future manned Mars missions. The present technique takes advantage of the strongly polarized nature of Raman scattering. It is shown to be discernable from unpolarized fluorescence interference by subtracting one polarized image from another. Both of these polarized images are obtained from a single laser pulse by using a polarization-separating calcite rhomb mounted in the imaging spectrograph. A demonstration in a propane-air flame is presented.

Wehrmeyer, Joseph A.↗

NASA NTRS2000

Raman Gas Species Measurements in Hydrocarbon-Fueled Rocket Engine Injector Flows

Rocket engine propellent injector development at NASA-Marshall includes experimental analysis using optical techniques, such as Raman, fluorescence, or Mie scattering. For the application of spontaneous Raman scattering to hydrocarbon-fueled flows a technique needs to be developed to remove the interfering polycyclic aromatic hydrocarbon fluorescence from the relatively weak Raman signals. A current application of such a technique is to the analysis of the mixing and combustion performance of multijet, impinging-jet candidate fuel injectors for the baseline Mars ascent engine, which will burn methane and liquid oxygen produced in-situ on Mars to reduce the propellent mass transported to Mars for future manned Mars missions. The Raman technique takes advantage of the strongly polarized nature of Raman scattering. It is shown to be discernable from unpolarized fluorescence interference by subtracting one polarized image from another. Both of these polarized images are obtained from a single laser pulse by using a polarization-separating calcite rhomb mounted in the imaging spectrograph. A demonstration in a propane-air flame is presented, as well as a high pressure demonstration in the NASA-Marshall Modular Combustion Test Artice, using the liquid methane-liquid oxygen propellant system

Wehrmeyer, Joseph↗

NASA NTRS1999

Raman Spectroscopy for Instantaneous Multipoint, Multispecies Gas Concentration and Temperature Measurements in Rocket Engine Propellant Injector Flows

Propellent injector development at MSFC includes experimental analysis using optical techniques, such as Raman, fluorescence, or Mie scattering. For the application of spontaneous Raman scattering to hydrocarbon-fueled flows a technique needs to be developed to remove the interfering polycyclic aromatic hydrocarbon fluorescence from the relatively weak Raman signals. A current application of such a technique is to the analysis of the mixing and combustion performance of multijet, impinging-jet candidate fuel injectors for the baseline Mars ascent engine, which will bum methane and liquid oxygen produced in-situ on Mars to reduce the propellent mass transported to Mars for future manned Mars missions. The present technique takes advantage of the strongly polarized nature of Raman scattering. It is shown to be discernable from unpolarized fluorescence interference by subtracting one polarized image from another. Both of these polarized images are obtained from a single laser pulse by using a polarization-separating calcite rhomb mounted in the imaging spectrograph. A demonstration in a propane-air flame is presented.

Wehrmeyer, Joseph A.↗

NASA NTRS2001

Raman Spectroscopy for Instantaneous Multipoint, Multispecies Gas Concentration and Temperature Measurements in Rocket Engine Propellant Injector Flows

Propellant injector development at MSFC includes experimental analysis using optical techniques, such as Raman, fluorescence, or Mie scattering. For the application of spontaneous Raman scattering to hydrocarbon-fueled flows a technique needs to be developed to remove the interfering polycyclic aromatic hydrocarbon fluorescence from the relatively weak Raman signals. A current application of such a technique is to the analysis of the mixing and combustion performance of multijet, impinging-jet candidate fuel injectors for the baseline Mars ascent engine, which will burn methane and liquid oxygen produced in-situ on Mars to reduce the propellant mass transported to Mars for future manned Mars missions. The present technique takes advantage of the strongly polarized nature of Raman scattering. It is shown to be discernable from unpolarized fluorescence interference by subtracting one polarized image from another. Both of these polarized images are obtained from a single laser pulse by using a polarization-separating calcite rhomb mounted in the imaging spectrograph. A demonstration in a propane-air flame is presented.

Wehrmeyer, Joseph A.↗

DOE OSTI2016

Nitride Fuel Potential for Power Uprates

This work presents the methodology and current results for design analysis of grid supported pressurized water reactor cores using uranium nitride (UN) fuel in square arrays. Uranium nitride has a higher theoretical density and higher thermal conductivity than uranium oxide, allowing for lower fuel temperatures, longer cycle length and higher power densities with similar enrichment. In order to avoid the UN and high temperature water reaction, silicon carbide cladding has been proposed in place of Zircaloy cladding. The analysis aims at finding the maximum thermal power over a range of bundle geometries (rod diameter and pitch). The same methodology is applied to the design of UO{sub 2} oxide fueled cores to provide a fair comparison of the achievable power rating between the two fuel types. Steady-state limits are considered, including fuel bundle pressure drop, minimum departure from nucleate boiling ratio (MDNBR), fuel temperature, fuel rod vibrations and pin fretting and sliding wear. Transients such as loss of flow and overpower accident will be considered. A steady state analysis was undertaken to determine the maximum achievable power that can be sustained by square array fuel assemblies loaded with nitride and oxide fuels with same or better safety performances as the reference design. Steady-state design limits were applied including MDNBR, fuel bundle pressure drop, fuel temperature, cumulative sliding and fretting wear. The major conclusions of this study are as follows: 1) It is possible to achieve significant power increase for UN and UO{sub 2} compared to the reference core power output of 3400 MWth with smaller but more numerous rods and higher pitch over diameter ratios. A power uprate of 25% can be reached according to the VIPRE-MATLAB interface for full core analysis with the same number of spacer grids, and 32% according to the new MATLAB script for single hot channel analysis, with five more spacer grids. For this latter core, a higher enrichment would be required. 2) The nitride fuel temperature constraint from dissociation doesn't influence steady state performances as other design constraints such as MDNBR and pressure loss are more restrictive. The oxide fuel temperature constraint from fission gas release is reached in part of the study domain, but not in the region that allows for possible uprates. 3) As a result, the thermal hydraulic performance of UN and UO{sub 2} are similar. Differences in possible power uprates will arise from fretting and sliding wear. Wear depends of the time spent by the fuel in the core, which depends on burnup and heavy metal inventory. UN being denser, it can allow for power uprates or increased cycle length. There is a trade off between power uprates and cycle length with regards to fuel pin wear. Reducing fuel pin wear by reducing cycle length can allow for higher thermal power. This affects the plants' economics as well. This work will be completed by a transient analysis using CASMO4E, SIMULATE3 and SIMULATE3k to model the neutronics of a nitride fueled core. The transient performances will be used to determine the maximum power uprates while performing as well or better during transients as the reference design. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗