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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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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Modeling Heat Pipes with Non-Condensable Gases

The report showcases advancements in modeling heat pipes, considering both scenarios with and without non-condensable gases. To achieve this, two distinct modeling approaches are juxtaposed. Firstly, the effective conduction model, implemented in the MOOSE-based code Sockeye, is employed. Secondly, a first-of-a-kind two-phase Euler-Euler Computational Fluid Dynamics (CFD) model is developed using the STAR-CCM+ code. Both models undergo validation against experimental data, acknowledging the inherent uncertainties associated with each modeling assumption. Interestingly, the non-tuned CFD model surpasses the performance of the calibrated conduction model for heat pipes operating under both conditions: with and without non-condensable gases. It's worth noting, however, that the CFD models entail significantly longer runtimes compared to the conduction models. Nevertheless, the insights garnered from the CFD model shed invaluable light on the intricate operational dynamics of heat pipes. Future work involves broadening the validation scope of these models and continuing their development to enhance their utility as robust tools for heat pipe design and operational support.

42 ENGINEERING↗
DOE OSTI2025

Evaporator Temperature Transient Testing of a High-Performance Sodium Filled Heat Pipe

Heat pipes are two-phase heat transfer devices that enable passive removal of heat from the reactor core to the power conversion system in heat pipe-cooled microreactor designs. Experimental investigations of heat pipe transients are needed for technology demonstration, verification and validation of numerical codes, and the establishment of regulatory requirements. The Single Primary Heat Extraction and Removal Emulator (SPHERE) facility at Idaho National Laboratory (INL) serves as a platform for evaluating the dynamic response of high-temperature heat pipes under a variety of operating conditions. The present work details the experimental investigation of a high-performance, defined as over 2 kW sodium heat pipe subjected to rapid input power fluctuations induced by sudden changes in the evaporator temperature setpoint. In addition, the heat pipe was subjected to an asymmetrical heat load where a subset of heaters operated at 30% and 70% below their nominal power. These experimental conditions were chosen to simulate thermal and operational stresses expected to be encountered in microreactors to provide data on heat pipe behavior during such important transient events. Key data and performance metrics, including time series of temperatures and strains, axial temperature profiles, thermal response times, and heat transfer capabilities, the thermal output over thermal input, were reported and discussed. The results highlight the resilience of heat pipes, revealing their potential to maintain thermal stability and efficiency under varying power loads. Lastly, the paper concludes with a discussion on the significance of the results and their implications for future research.

22 - GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2016

Revisiting low-fidelity two-fluid models for gas–solids transport

Two-phase gas–solids transport models are widely utilized for process design and automation in a broad range of industrial applications. Some of these applications include proppant transport in gaseous fracking fluids, air/gas drilling hydraulics, coal-gasification reactors and food processing units. Systems automation and real time process optimization stand to benefit a great deal from availability of efficient and accurate theoretical models for operations data processing. However, modeling two-phase pneumatic transport systems accurately requires a comprehensive understanding of gas–solids flow behavior. In this study we discuss the prevailing flow conditions and present a low-fidelity two-fluid model equation for particulate transport. The model equations are formulated in a manner that ensures the physical flux term remains conservative despite the inclusion of solids normal stress through the empirical formula for modulus of elasticity. A new set of Roe–Pike averages are presented for the resulting strictly hyperbolic flux term in the system of equations, which was used to develop a Roe-type approximate Riemann solver. The resulting scheme is stable regardless of the choice of flux-limiter. The model is evaluated by the prediction of experimental results from both pneumatic riser and air-drilling hydraulics systems. We demonstrate the effect and impact of numerical formulation and choice of numerical scheme on model predictions. We illustrate the capability of a low-fidelity one-dimensional two-fluid model in predicting relevant flow parameters in two-phase particulate systems accurately even under flow regimes involving counter-current flow.

42 ENGINEERING↗
DOE OSTI2020

RELAP-7 Application and Enhancement for FLEX Strategies and ATF Behavior under Extended Loss of AC Power Conditions

This report summarizes the results of a three-year research project sponsored by the U.S. Department of Energy (DOE) Nuclear Energy University Program (NEUP) to enhance and apply the RELAP-7 code by adding and improving several important components (e.g., a mechanistic Reactor Core Isolation Cooling (RCIC) system model) for thermal hydraulic studies of LWRs under ELAP conditions and evaluating the time available for transition to portable FLEX equipment. The project team included University of Massachusetts–Lowell, The Ohio State University, Texas A&M University, Idaho National Laboratory and Oak Ridge National Laboratory. In the Fukushima accident, it was found that the RCIC system played a crucial role in delaying core meltdown by almost three days in Fukushima Daiichi Unit 2, because of self-regulated operation of the steam driven RCIC turbine-pump injection system. Steam flow in the convergent-divergent nozzles of the RCIC Terry turbine is two-phase non-equilibrium transonic flow with homogenous nucleation condensation. To more accurately predict the dynamic process and behavior of the transonic compressible steam flow, a one-dimensional transient two-phase analytical model is presented. A simplified four-fluid model was employed in the present work with the consideration of four separate fluid fields: vapor, liquid film, entrained droplets and condensed droplets. The mass, momentum and energy interactions between the fluids were considered and modeled. An extended seven-equation non-equilibrium critical flow model was developed to obtain the critical pressure and velocities of each phase at the nozzle throat. To predict the wetness in the divergent section, a mechanistic nucleation condensation model was integrated in the nozzle analysis model, considering the generation and consequent growth of droplets. The governing differential equations on a staggered grid were discretized using the second-order Lax-Wendroff scheme with a flux limiter, and the Semi-Implicit Method for Pressure-Linked Equation (SIMPLE) algorithm was employed to solve the discrete linear system. To demonstrate the predictability and reliability of the physical models and the numerical method proposed in the present work, three representative nozzles were modeled and simulated. The results show good agreement with the available experimental data, even for condensation shock. Then, the 1D nozzle model was employed to obtain nozzle flow tables of the Terry turbine nozzle for different working pressures which can cover the operation pressure range of the RCIC system. A mechanistic RCIC turbine-pump system model was developed and implemented in the system code TRACE to simulate dynamic responses of the RCIC system under Beyond Design Basis Accident (BDBA) conditions. The turbine-pump governing equations are based on the control volume approach of the angular momentum balance. The physics based mechanistic RCIC model was developed using the TRACE control system components (i.e., signal variables, control blocks, and tables), and incorporated into a TRACE boiling water reactor (BWR) model. The TRACE model in this report has a detailed nodalization of the reactor pressure vessel (RPV), and all of the major flow paths and system components, including the safety relief valves (SRVs) and the containment suppression pool and drywell. Based on the nozzle flow tables generated from the 1D nozzle model developed, the turbine drive torque can be calculated from table lookup. Since the detailed specifications of the RCIC pump are unavailable, the homologous curves for a Bingham pump were used in the current pump component. A station black-out (SBO) accident test problem was selected to demonstrate the TRACE RCIC model. The short-term SBO simulations were performed for two cladding materials: Zircaloy and FeCrAl, to demonstrate the effect of the accident tolerant fuel cladding on fuel heat-up under BDBA accident conditions. The wetwell plays a vital safety role in SBO and other BWR accident scenarios in that it can reduce containment pressure and supply additional core make-up water. The suppression pool temperature distribution has a very large impact on both RPV and containment pressure. Thus, another novel contribution of the project comes mainly from an improved, systems-level wetwell model which can capture buoyancy-induced thermal stratification effects due to steam injection and condensation. A two-zone stratified wetwell model has been implemented in RELAP-7 and some results from that model are presented. This wetwell model is capable of simulating thermal stratification due to a low steam mass injection rate. With a low mass flow rate, the model assumes that all the steam condenses within the pipe and the resulting plume can be approximated with a purely buoyant, heat-source driven model. The wetwell model developed with these assumptions is adequate to simulate slow transients such as extended SBO transients.

42 ENGINEERING↗
DOE OSTI2016

Strongly coupled fluid-particle flows in vertical channels. I. Reynolds-averaged two-phase turbulence statistics

Simulations of strongly coupled (i.e., high-mass-loading) fluid-particle flows in vertical channels are performed with the purpose of understanding the fundamental physics of wall-bounded multiphase turbulence. The exact Reynolds-averaged (RA) equations for high-mass-loading suspensions are presented, and the unclosed terms that are retained in the context of fully developed channel flow are evaluated in an Eulerian–Lagrangian (EL) framework for the first time. A key distinction between the RA formulation presented in the current work and previous derivations of multiphase turbulence models is the partitioning of the particle velocity fluctuations into spatially correlated and uncorrelated components, used to define the components of the particle-phase turbulent kinetic energy (TKE) and granular temperature, respectively. The adaptive spatial filtering technique developed in our previous work for homogeneous flows [J. Capecelatro, O. Desjardins, and R. O. Fox, “Numerical study of collisional particle dynamics in cluster-induced turbulence,” J. Fluid Mech. 747, R2 (2014)] is shown to accurately partition the particle velocity fluctuations at all distances from the wall. Strong segregation in the components of granular energy is observed, with the largest values of particle-phase TKE associated with clusters falling near the channel wall, while maximum granular temperature is observed at the center of the channel. The anisotropy of the Reynolds stresses both near the wall and far away is found to be a crucial component for understanding the distribution of the particle-phase volume fraction. In Part II of this paper, results from the EL simulations are used to validate a multiphase Reynolds-stress turbulence model that correctly predicts the wall-normal distribution of the two-phase turbulence statistics.

42 ENGINEERING↗
DOE OSTI2016

Evaluating performance of two-group interfacial area transport equation for vertical small and large diameter pipes

In the two-fluid transport model, the coupling of mass, momentum and energy transfer between phases is highly dependent on interfacial area transfer terms. Several research efforts in the past have been focused on the development of an interfacial area transport equation model (IATE), in order to eliminate the drawbacks of static flow regime maps currently used in best-estimate thermal-hydraulic system codes. The IATE attempts to model the dynamics that are involved in two phase flows by accounting for the different interaction mechanisms affecting bubble transport in the flow. The further development and validation of IATE models has been hindered by the lack of adequate experimental data in regions beyond the bubbly flow regime. At the Helmholtz-Zentrum Dresden-Rossendorf (HZDR) experiments utilizing wire mesh sensors have been performed over all flow regimes, establishing a database of high-resolution (in space and time) data. Two sets of data from small and large diameter pipes fitted with wire mesh sensors is utilized in this work. Analysis of flow conditions in the bubbly, churn turbulent and annular flow regimes is presented. The performance of the Fu-Ishii two-group model is evaluated against small diameter database. Results indicate good performance (< 10% error) for small group 1 bubbles, and poor performance for large group 2 bubbles. The Smith two-group large diameter IATE model is evaluated for the large diameter database. In low void-fraction regimes, the Smith model performs well. In high void-fraction regimes, there is poor group-wise interfacial area prediction - however the total interfacial area is erroneously predicted well as group-wise errors compensate each other. Overall, the study suggests that further efforts and re-evaluation of closure terms are needed in order to extend the range of validity of the IATE models. (authors)

42 ENGINEERING↗
DOE OSTI2016

Simulating the Cranfield geological carbon sequestration project with high-resolution static models and an accurate equation of state

In this study, a field-scale carbon dioxide (CO 2 ) injection pilot project was conducted as part of the Southeast Regional Sequestration Partnership (SECARB) at Cranfield, Mississippi. We present higher-order finite element simulations of the compositional two-phase CO 2 -brine flow and transport during the experiment. High- resolution static models of the formation geology in the Detailed Area Study (DAS) located below the oil- water contact (brine saturated) are used to capture the impact of connected flow paths on breakthrough times in two observation wells. Phase behavior is described by the cubic-plus-association (CPA) equation of state, which takes into account the polar nature of water molecules. Parameter studies are performed to investigate the importance of Fickian diffusion, permeability heterogeneity, relative permeabilities, and capillarity. Simulation results for the pressure response in the injection well and the CO 2 breakthrough times at the observation wells show good agreement with the field data. For the high injection rates and short duration of the experiment, diffusion is relatively unimportant (high P clet numbers), while relative permeabilities have a profound impact on the pressure response. High-permeability pathways, created by fluvial deposits, strongly affect the CO 2 transport and highlight the importance of properly characterizing the formation heterogeneity in future carbon sequestration projects.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2021

Two-Phase Turbulence Statistics from High Fidelity Dispersed Droplet Flow Simulations in a Pressurized Water Reactor (PWR) Sub-Channel with Mixing Vanes

In the dispersed flow film boiling regime (DFFB), which exists under post-LOCA (loss-of-coolant accident) conditions in pressurized water reactors (PWRs), there is a complex interplay between droplet dynamics and turbulence in the surrounding steam. Experiments have accredited particular significance to droplet collision with the spacer-grids and mixing vane structures and their consequent positive feedback to the heat transfer recorded in the immediate downstream vicinity. Enabled by high-performance computing (HPC) systems and a massively parallel finite element-based flow solver—PHASTA (Parallel Hierarchic Adaptive Stabilized Transient Analysis)—this work presents high fidelity interface capturing, two-phase, adiabatic simulations in a PWR sub-channel with spacer grids and mixing vanes. Selected flow conditions for the simulations are informed by the experimental data found in the literature, including the steam Reynolds number and collision Weber number (Wec={40,80}), and are characteristic of the DFFB regime. Data were collected from the simulations at an unprecedented resolution, which provides detailed insights into the continuous phase turbulence statistics, highlighting the effects of the presence of droplets and the comparative effect of different Weber numbers on turbulence in the surrounding steam. Further, axial evolution of droplet dynamics was analyzed through cross-sectionally averaged quantities, including droplet volume, surface area and Sauter mean diameter (SMD). The downstream SMD values agree well with the existing empirical correlations for the selected range of Wec. The high-resolution data repository from the simulations herein is expected to be of significance to guide model development for system-level thermal hydraulic codes.

Saini, Nadish↗
DOE OSTI2022

Experimental and analytical study of the hydrodynamic and single and two-phase convective heat transfer performance of flexible PDMS microchannels with micropillar arrays

Various copper and silicon based thermal management systems are used in the cooling of electronics. However, the rigid nature of these materials along with their high thermal and electrical conductivity pose a difficulty in developing direct contact embedded flexible cooling systems that can offer robust cooling performance. The low density, thermal stability, chemical inertness, and electrical insulation of Polydimethylsiloxane (PDMS) make it an ideal material to develop lightweight direct contact thermal management systems for electronics. Its ease of fabrication with tunable flexibility provides the opportunity to go beyond traditional electronics and develop advanced active and passive thermal management systems for a wide–range of applications in foldable and wearable electronics, liquid cooling garments, microgravity, and electric motors. In this study, a flexible PDMS based microchannel with micropillar arrays, which enhance the thermal performance of the device through capillary-assisted flow, has been developed. The hydrodynamic and convection heat transfer performance of three PDMS wick pillar geometries, ranging from a porosity of 0.8–0.91, are investigated and compared under single-phase and two-phase conditions. Dielectric coolant FC-3283 is employed and permeability measurements are made for mass fluxes ranging from 53 kg/m 2 s to 369 kg/m 2 s. Given its conformability, the device demonstrates a deviation from Darcy’s Law, within the laminar regime, with an increasing permeability with mass flux at the rate of ~0.5–0.8 Darcy/(kg/m 2 s). A semi-analytical model has been developed and reported to quantify the conformability of the device. The heat transfer performance is experimentally evaluated using the same dielectric fluid for mass flux ranging from 105 kg/m 2 s to 420 kg/m 2 s with heat fluxes ranging from 1.5 W/cm 2 to 16 W/cm 2 . Heat transfer coefficients of up to 7000 W/m 2 K are observed, which are comparable to copper and silicon microchannels. The effect of porosity on the single phase thermal performance has been evaluated against the pumping power to provide a basis for thermal management system design. Finally, high-speed imaging is performed to study the two-phase flow characteristics to provide insight into the vapor formation and removal.

42 ENGINEERING↗
DOE OSTI2024

FY24 Report on Water NSTF Testing: Lower Tank Inlet Piping Configuration

The following report serves as a summary of the accomplishments and testing results by the Natural convection Shutdown heat removal Test Facility (NSTF) experimental program over the past 12-month period. A major activity included reconfiguration of the chimney piping geometry which altered the discharge position into the tank from the original 50% tank height to a new lower position at a 10.9% tank height. This modification increases the volume of available coolant thus extending long-term operating capacity, however also results in a decreased liquid driving head which has the potential to reduce the natural circulation efficiency and decrease overall performance. Examination of the tradeoffs for these two configurations is an area of interest for RCCS designers and drove planned test activities this year. Ten matrix tests were performed in FY24, totaling 195 hours of heated operations and 12.9 MWh of electrical heating throughout the year, with eight classified as Accepted per NQA-1 and two classified as Trending. Testing prior to the facility reconfiguration examined the facility response to throttling at the tank inlet, demonstrating increased sensitivity of flow instabilities to throttling within the two-phase region when compared to throttling at the lower sensitivity single-phase inlet region. Testing after the chimney reconfiguration began with a baseline test at conditions of 80% inventory fill and prototypic thermal power input of 2.1 MW t . In addition to establishing a reference for nominal system behavior and performance, repeat testing with multiple subsequent runs demonstrated strong repeatability between tests performed at the same conditions in this new configuration. These tests also examined if influences would occur to system behavior with installation of new higher-resolution instrumentation within the upper chimney. In this critical region where boiling and flashing phenomena dominate, the test results provided confidence that the new instrumentation does not uncharacteristically influence the observed behaviors. An inventory parametric series was then initiated to examine system behavior with the new chimney configuration at six varying initial inventory levels, ranging from high 80% to low 20% fill. Two-phase oscillations with similar peak and mean flow rates were observed when comparing to the previous mid tank configuration. Generally, similar system response trends with inventory were also observed, such as two phase oscillations suppressing as inventories were lowered. However, in one absolute inventory comparison at the highest fill of 80%, flow oscillations saw a gradual growth over the 4 hours of two-phase operation in the new lower tank inlet configuration, opposite of the gradual dampening observed in the mid tank inlet configuration. This can be attributed to, in part, a greater hydrostatic head pressure above the two-phase discharge region where the boiling front is developed. Furthermore, the change resulted in greater sensitivity to liquid degassing phenomena during single-phase heating, causing loop instabilities to form which trigged moderate flow degradation during the period approaching saturation and boiling conditions. This behavior had been observed previously under some conditions but was a common occurrence in recent testing with the newer lower tank inlet configuration. Initial observations from these first data sets suggest an overall larger window of stability for the mid tank inlet configuration compared to the lower tank inlet. Lastly, the lowest inventory fill test was repeated over an extended testing window to examine depletion behavior. Natural circulation flow and effective heat removal performance were observed during most of the testing period; only after the tank became fully drained (0% fill) did flow stagnate and violent geysering events occur. This early observation confirms one relative advantage over the mid tank inlet configuration, which stagnated under comparable conditions at ~20% inventory remaining in the tank.

42 ENGINEERING↗
DOE OSTI2016

Improving performance of two-group interfacial area transport equation models using genetic algorithms and high resolution experimental data

In the two-fluid transport model, the coupling of mass, momentum and energy transfer between phases is highly dependent on interfacial area transfer terms. Several research efforts in the past have been focused on the development of an interfacial area transport equation model (IATE), in order to eliminate the drawbacks of static flow regime maps currently used in best-estimate thermal-hydraulic system codes. The IATE attempts to model the dynamics that are involved in two phase flows by accounting for the different interaction mechanisms affecting bubble transport in the flow. In general, current IATE models perform poorly in high void fraction flow regimes. As both models depend on closure relations that require empirically determined coefficients, a genetic algorithm is implemented to study their optimization. The preliminary study indicates that improvements are achievable by application of the genetic algorithm. Optimization of coefficients for an entire set of high-resolution wire mesh sensor (WMS) data provided a single set of optimal coefficients. The application of WMS-optimized coefficients to external tests improved IATE performance for similar hydraulic diameters and provided a neutral change in performance for significantly smaller/larger hydraulic diameters. This is a crucial outcome as an optimized set of coefficients that provide significant improvement for a subset of experimental data - is shown to benefit performance in external data for which the coefficients are not specifically optimized. (authors)

42 ENGINEERING↗
DOE OSTI2024

FY-24 Progress on Computational Modeling of the Water Based NSTF

This report summarizes the computational modeling of the Natural Convection Shutdown Heat Removal Test Facility (NSTF) completed in FY24. This year’s modeling campaign focuses on the continual testing of the RELAP5 model against experimental data. Several fault cases were simulated with the RELAP5 model in FY23 to study the accuracy of the model under complex flow conditions. Similarly, in FY24, a case is simulated where the chimney outlet is throttled with a valve while the flow is undergoing two-phase oscillations. The purpose of this case is to study the effects of increasing pressure drop in the two-phase region on the system behavior. Even though the model is able to capture the experimental data qualitatively, it overpredicts the pressure drops experienced by the flow in the two-phase regime. Nevertheless, the model and the experiment show that oscillations are stabilized with increased pressure drop in the two-phase region.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Eddy Current Flow Meter Measurements and Modeling Validation

The goal of the eddy current flow meter (ECFM) is to monitor velocities and temperatures of conductive liquid metals. The ECFM can also detect voids in two-phase liquid metal flows. Measurement of these flows can greatly improve the accuracy of the empirical formulas used for fluid dynamics near the reactor core and aid in mapping any non-uniformities in fluid flow such as estimates of temperature and phase. While the eventual goal is to develop the ECFM for the liquid sodium surrounding the Versatile Test Reactor (VTR) core, this report focuses on modeling and experimental validation of ECFM for a moving solid test rod and for liquid mercury in the Target Test Facility (TTF) flow loop to better understand and further develop ECFM measurement capabilities by validating model predictions with benchmark experiments. Eventually the models could be used to design and optimize future ECFMs for specific applications such as monitoring flow within the VTR pool.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2016

Influence of phase connectivity on the relationship among capillary pressure, fluid saturation, and interfacial area in two-fluid-phase porous medium systems

Here, multiphase flow in porous medium systems is typically modeled using continuum mechanical representations at the macroscale in terms of averaged quantities. These models require closure relations to produce solvable forms. One of these required closure relations is an expression relating fluid pressures, fluid saturations, and, in some cases, the interfacial area between the fluid phases, and the Euler characteristic. An unresolved question is whether the inclusion of these additional morphological and topological measures can lead to a non-hysteretic closure relation compared to the hysteretic forms that are used in traditional models, which typically do not include interfacial areas, or the Euler characteristic. We develop a lattice-Boltzmann (LB) simulation approach to investigate the equilibrium states of a two-fluid-phase porous medium system, which include disconnected now- wetting phase features. The proposed approach is applied to a synthetic medium consisting of 1,964 spheres arranged in a random, non-overlapping, close-packed manner, yielding a total of 42,908 different equilibrium points. This information is evaluated using a generalized additive modeling approach to determine if a unique function from this family exists, which can explain the data. The variance of various model estimates is computed, and we conclude that, except for the limiting behavior close to a single fluid regime, capillary pressure can be expressed as a deterministic and non-hysteretic function of fluid saturation, interfacial area between the fluid phases, and the Euler characteristic. This work is unique in the methods employed, the size of the data set, the resolution in space and time, the true equilibrium nature of the data, the parameterizations investigated, and the broad set of functions examined. The conclusion of essentially non-hysteretic behavior provides support for an evolving class of two-fluid-phase flow in porous medium systems models.

36 MATERIALS SCIENCE↗
DOE OSTI2018

Commercialization Opportunity SFAI: An acoustic-based method for measuring composition and flow in containers, vessels, and pipes

The need to accurately discern the characteristics of materials within closed containers non-invasively is a problem that plagues many industrial sectors. In particular, characterizing multi-phase flow in pipes and other infrastructure is an ongoing challenge for many industries. Swept Frequency Acoustic Interferometry, or SFAI, and related technologies represent a portfolio that uses high-frequency sound to characterize liquids, gasses, mixtures, emulsions, and other fluids inside pipes and containers. SFAI offers the potential to measure material characteristics and two -and three -phase flows within pipes including flow rates and water- and gas-volume fractions. Such measurements can take place noninvasively both in accessible infrastructure and potentially downhole.

47 OTHER INSTRUMENTATION↗
DOE OSTI2019

Preliminary Design Study for an Eddy Current Flow Meter for Versatile Test Reactor

The eddy current flow meter (ECFM) serves the purpose of monitoring velocities and temperatures of conductive liquid coolant surrounding nuclear reactor cells. The ECFM can also detect voids in two-phase liquid metal flows. Measurement of this flow in reactor cells can greatly improve the accuracy of the empirical formulas used for fluid dynamics near the reactor core, as well as, aid in mapping any non-uniformities in fluid flow, its temperature estimation and phase. With modeling and experimental verification, an extensible ECFM for multiple facilities and environments can lead to an understanding of the liquid coolant flow; while saving cost of calibration and development. This can be done by characterizing the ECFM performance based on its parameters and then optimizing a sensor for a given use case. Simulation results using an ECFM and an aluminum rod medium are presented and discussed herein. Additionally, liquid metal simulations for Mercury and Galinstan will compare the ECFM behavior for different liquid velocities and excitation frequencies. After sensor calibration curves are generated and experimentally verified, ECFMs can be developed and deployed using the model introduced.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2019

Oil and gas flow through fractures and along interfaces in well cement

A number of wells at the Strategic Petroleum Reserve (SPR) have shown sustained, positive pressure (referred to as sustained casing pressure or SCP) in the cemented annulus behind the production casing. To better understand how SCP may develop for SPR conditions, we conducted gas and oil flow tests on cement specimens with flaws including cement fractures and discrete interfaces along a cement-steel contact. Many specimens were tested initially with gas, followed by oil, and finally with gas again to identify how the fluid type may affect the flow through flaws in the well cement. Nitrogen was used as the gas, and silicone oil with properties similar to typical crude oil was used in most tests. One set of measurements were made with crude oil. Composite steel-cement specimen with corroded steel were also tested. For both gas and oil tests, the measured flow test data were used to interpret permeability and, assuming the cubic law for flow between parallel plates, the corresponding hydraulic aperture of the flaw. The hydraulic apertures for the flawed specimens ranged from about 20 to >100 μm, which corresponds to permeabilities of about 10 -14 to 10 -12 m 2 , respectively; these hydraulic apertures are consistent with the range of values interpreted from field measurements on leaky wells. Observed differences between the flow of gas and oil were attributed to a number of factors, including non-linear flow of gas, possible blocking of flow paths by solids within the crude oil, two-phase gas and oil flow and the presence of residual oil in the cement flaw. Furthermore, we determined that corroded steel itself is permeable. Using input values consistent with the gas and oil flow measurements, we conducted one-dimensional simulations of gas and oil flow through cemented annulus systems to investigate the role of flaw size and fluid type on the expected response (i.e., pressure build-up) in the annular cement.

02 PETROLEUM↗
DOE OSTI2019

High Performance Computing to Enable Next-Generation Low-Temperature Waste Heat Recovery

US manufacturing industry fails to recover an estimated 900 trillion BTUs of low-temperature waste heat from its processes each year. A grand research challenge has been to develop waste heat recovery technology that can be applied to industrial manufacturing processes and vehicle operations. The Oak Ridge National Laboratory (ORNL)/Eaton research team performed computational research and development to design an innovative direct-contact heat exchanger (DCHE) technology to deliver low-cost, compact, longer-lifetime, high-efficiency waste heat recovery that is optimized for a low-temperature organic Rankine cycle. ORNL resources and expertise in high performance computing (HPC) and multiphase flows were utilized to realize this goal while advancing the fundamental understanding of two-phase, two-immiscible-fluid turbulent flow heat transfer for heat exchangers. In the first stage of the project, a computational fluid dynamics (CFD) model of a DCHE was developed. Verification and limited validation of the numerical solution were performed using experimental data from published literature. To support efforts in verification and validation, two-dimensional CFD models were also developed with the objective of investigating different boundary conditions to reach converged, steady-state solutions.Based on benchmarking efforts, a baseline industry-grade design of a DCHE was developed, which consists of two horizontal pipes of different cross-sectional areas – joined by a converging-diverging nozzle in the middle and relies on a three-phase system with co-current flows for operation. Evaporation of the cold liquid (n-pentane or methanol) by the hot liquid water occurs in the first pipe. The first pipe contains two inlets for liquid water and liquid pentane (or liquid methanol). The second pipe with the larger cross-sectional area serves as a gravity-driven phase-separator. It contains two outlets that are staggered to avoid entrainment of the liquid water phase by the gas phase. This baseline design resulted from several trial-and-error evaluations using two-dimensional CFD models. Confirmatory three-dimensional CFD models were also run for different mass flow rates and inlet temperatures (inlet water temperature ranging from 50°C to 90°C), and efficiency plots were produced to fully characterize the proposed industrial-grade design of the DCHE.

97 MATHEMATICS AND COMPUTING↗