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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↗

DOE OSTI2016

Stratification of a two-phase monodisperse system in a plane laminar flow

A thermodynamic approach is used to describe the distribution of particles of a disperse phase in a plane laminar flow. The effect of the density, shape, and velocity of disperse particles in the flow is considered. Conditions are described under which various modes of stratification of the flow (near-wall, central, intermediate, and multilayer modes) arise. The equilibrium distributions obtained are self-similar; this allows one to compare the behavior of colloidal, highly disperse, coarsely disperse, and coarse-grain systems for various shear velocities and flow widths.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2015

Virtual Flow Simulator

Virtual Flow Simulator (VFS) is a state-of-the-art computational fluid mechanics (CFD) package that is capable of simulating multi-physics/multi-phase flows with the most advanced turbulence models (RANS, LES) over complex terrains. The flow solver is based on the Curvilinear Immersed Boundary (CURVIB) method to handle geometrically complex and moving domains. Different modules of the VFS package can provide different simulation capabilities for specific applications ranging from the fluid-structure interaction (FSI) of solid and deformable bodies, the two-phase free surface flow solver based on the level set method for ocean waves, sediment transport models in rivers and the large-scale models of wind farms based on actuator lines and surfaces. All numerical features of VFS package have been validated with known analytical and experimental data as reported in the related journal articles. VFS package is suitable for a broad range of engineering applications within different industries. VFS has been used in different projects with applications in wind and hydrokinetic energy, offshore and near-shore ocean studies, cardiovascular and biological flows, and natural streams and river morphodynamics. Over the last decade, the development of VFS has been supported and assisted with the help of various United States companies and federal agencies that are listed in the sponsor lists. In this version, VFS-Wind contains all the necessary modeling tools for wind energy applications, including land-based and offshore wind farms. VFS is highly scalable to run on either desktop computers or high performance clusters (up to 16,000 CPUs). This released version comes with a detailed user’s manual and a set of case studies designed to facilitate the learning of the various aspects of the code in a comprehensive manner. The included documentation and support material has been elaborated in a collaboration effort with Sandia National Labs under the contract DE-EE0005482. The VFS-Wind source code is distributed under the GNU General Public License (GPL 2.0), offering to the community the flexibility to use and expand the capabilities of the package. We note that future publications including academic journals that result from the use of VFS must be cited appropriately under the GPL v.2 license agreement.

Yang, Xiaolei↗

DOE OSTI2015

Virtual Flow Simulator

Calderer, Antoni↗

DOE OSTI2022

NUMERICAL INVESTIGATION OF AIR DEHUMIDIFICATION THROUGH WATER DROPLETS DIELECTROPHORESIS

This paper numerically investigated the dehumidification of moist airflow in a converging rectangular duct with electrically enhanced condensation. The aim was to develop a condensation model that predicted water vapor condensation by employing the dielectrophoresis principle. The charged droplets were injected into the computational domain to produce a gradient electric field. The dielectrophoretic interaction between the droplets and vapor molecules of the humid air resulted in local water vapor condensation at the vapor and liquid droplet interface. This phenomenon is described in detail in this paper. A hybrid Eulerian-Lagrangian solver SprayFoam was developed based on OpenFOAM® to simulate condensation in two-phase gas-liquid mixtures. The following developments were made based on the standard compressible multiphase flow solver SprayFoam in OpenFOAM®: (1) Eulerian solver for gas phase (2) multi-component species transport, and (3) Lagrangian solver for gas-droplet two-phase flows and sub-models for liquid droplets. The newly developed numerical model was experimentally validated with data from a series of tests conducted in the authors' laboratory. The results showed that the simulations followed the same trends as the data, and the model predicted the condensation due to the electro-spray injection process in the air stream. The injected water droplets, which are electrically charged to their Rayleigh limits, increased in size while wiping out the humidity from the air. The simulations indicated that the dehumidification was about 1% for 0.5 cubic feet per minute airflow rate. Scaling up to larger flows is a future follow-up work.

Yel Mahi, *Maliha↗

DOE OSTI2017

Steady-state supercritical CO 2 and brine relative permeability in Berea sandstone at different temperature and pressure conditions

In this study, we measure steady-state two-phase supercritical CO 2 -brine relative permeabilities in a 61 cm-long Berea sandstone core at three different conditions (408C and 12.41 MPa, 408C and 8.27 MPa, and 608C and 12.41 MPa) under primary drainage. We use pressure taps to obtain pressure drops of individual sections of the core, and X-ray Computed Tomography (CT) to obtain in situ saturation profiles, which together help to mitigate the capillary end effect. We include previously measured relative permeabilities at 208C and 10.34 MPa, and compare all the data using both an eye-test and a statistical test. We find no appreciable temperature and pressure dependence of CO 2 relative permeability within 20–608C and 8.27–12.41 MPa. We find slight changes in the brine relative permeability between supercritical CO 2 conditions (40–608C and 8.27–12.41 MPa) and the liquid CO 2 condition (208C and 10.34 MPa). The temperature and pressure independence of CO 2 relative permeability has been previously recognized and reassured in this work using a capillary-effect-free method. This allows one to use a single CO 2 relative permeability curve in modeling two-phase CO 2 flow within 20–608C and 8.27–12.41 MPa.

58 GEOSCIENCES↗

DOE OSTI2017

Investigations of effect of phase change mass transfer rate on cavitation process with homogeneous relaxation model

The super high fuel injection pressure and micro size of nozzle orifice has been an important development trend for the fuel injection system. Accordingly, cavitation transient process, fuel compressibility, amount of noncondensable gas in the fuel and cavitation erosion have attracted more attention. Based on the fact of cavitation in itself is a kind of thermodynamic phase change process, this paper takes the perspective of the cavitation phase change mass transfer process to analyze above mentioned phenomenon. The two-phase cavitating turbulent flow simulations with VOF approach coupled with HRM cavitation model and U-RANS of standard k-ε turbulence model were performed for investigations of cavitation phase change mass transfer process. It is concluded the mass transfer time scale coefficient in the Homogenous Relaxation Model (HRM) representing mass transfer rate should tend to be as small as possible in a condition that ensured the solver stable. At very fast mass transfer rate, the phase change occurs at very thin interface between liquid and vapor phase and condensation occurs more focused and then will contribute predictably to a more serious cavitation erosion. Both the initial non-condensable gas in fuel and the fuel compressibility can accelerate the cavitation mass transfer process.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2023

Two-phase separator device for removing condensate or particulate from a gas stream

This disclosure provides a two-phase separator device for separating condensate or particulate from a gas stream. In some implementations, the separator device removes water from air and may operate under micro-gravity conditions. The gas stream flows through the two-phase separator device and passes through a rotatable vane assembly along a flow path without being redirected in another flow path. Condensate or particulate in the gas stream is impacted by a plurality of vanes of the rotatable vane assembly, and the condensate is captured by features formed within the plurality of vanes. The captured condensate is accelerated radially outwardly along the each of the plurality of vanes towards a sloped inner wall, and further moved along the sloped inner wall in a direction against the flow path of the gas stream during rotation.

Cognata, Thomas↗

DOE OSTI2016

A multiscale restriction-smoothed basis method for high contrast porous media represented on unstructured grids

A wide variety of multiscale methods have been proposed in the literature to reduce runtime and provide better scaling for the solution of Poisson-type equations modeling flow in porous media. We present a new multiscale restricted-smoothed basis (MsRSB) method that is designed to be applicable to both rectilinear grids and unstructured grids. Like many other multiscale methods, MsRSB relies on a coarse partition of the underlying fine grid and a set of local prolongation operators (multiscale basis functions) that map unknowns associated with the fine grid cells to unknowns associated with blocks in the coarse partition. These mappings are constructed by restricted smoothing: Starting from a constant, a localized iterative scheme is applied directly to the fine-scale discretization to compute prolongation operators that are consistent with the local properties of the differential operators. The resulting method has three main advantages: First of all, both the coarse and the fine grid can have general polyhedral geometry and unstructured topology. This means that partitions and good prolongation operators can easily be constructed for complex models involving high media contrasts and unstructured cell connections introduced by faults, pinch-outs, erosion, local grid refinement, etc. In particular, the coarse partition can be adapted to geological or flow-field properties represented on cells or faces to improve accuracy. Secondly, the method is accurate and robust when compared to existing multiscale methods and does not need expensive recomputation of local basis functions to account for transient behavior: Dynamic mobility changes are incorporated by continuing to iterate a few extra steps on existing basis functions. This way, the cost of updating the prolongation operators becomes proportional to the amount of change in fluid mobility and one reduces the need for expensive, tolerance-based updates. Finally, since the MsRSB method is formulated on top of a cell-centered, conservative, finite-volume method, it is applicable to any flow model in which one can isolate a pressure equation. Herein, we only discuss single and two-phase incompressible models. Compressible flow, e.g., as modeled by the black-oil equations, is discussed in a separate paper.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2021

ANTS

The ANTS code (Alternate Non-Linear Two-phase Solver) is based on a novel non-linear solution algorithm for the solution of the two-phase, subchannel fluid equations. It achieves its performance through decoupling of the two-phase momentum equations (axial and transverse) from the axial phasic mass and energy equations which allows for a nested non-linear iteration scheme. This enables a plane-by-plane solution which the inner iteration focuses on a reduced non-linear equation set for the primitives in phasic mass flow rate, enthalpy and void for each node edge. Single node edges are coupled as part of the outer iteration via surface mass fluxes which appear as source terms in the inner iteration scheme. The outer iteration readily accommodates two-phase flow phenomena closure relationships for subchannel mixing and void drift. A primary feature is the use of a non-staggered mesh computational mesh and steady-state iterative solver in contrast to all existing subchannel codes.

Kropaczek, David J↗

DOE OSTI2016

Pairwise Force Smoothed Particle Hydrodynamics model for multiphase flow: Surface tension and contact line dynamics

Not Available

Tartakovsky, Alexandre M.↗

DOE OSTI2024

Boiling-Water Reactor Testing Capability in the Advanced Test Reactor

I-Loop is an irradiation facility that is currently being installed at the Advanced Test Reactor. It is a two-loop test facility capable of performing Light Water Reactor (LWR) irradiations in prototypic coolant conditions. The two loops are being installed to be capable of both Boiling Water Reactor (BWR) and Pressurized Water Reactor (PWR) pressure, temperature, and chemistry environments. Each loop is nominally dedicated as a BWR or PWR for simplicity of operations. In-reactor water loop testing that an I-Loop provides is key to the deployment of new accident tolerant fuel technologies and other advanced LWR fuel concepts. Currently, pressurized water loops are the only testing facilities available to test BWR fuel concepts. Their test environments are non-prototypic at higher pressure/temperature and at single-phase fluid flow conditions. This void in the LWR test bed capabilities is one that the I-Loop is uniquely situated to provide. This report discusses the mechanical design, thermal hydraulic calculations, and neutronic calculations of a proposed standard experiment of accident tolerant BWR fuel concepts. Mechanical design examines the geometry and features of the main components. Thermal hydraulic calculations examine the modeling and results of the two-phase flow options available. Lastly, neutronic calculations examine the Monte Carlo analysis of enrichment, heat rates, and flux spectrum.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2020

Mixed-flow design for microfluidic printing of two-component polymer semiconductor systems

The rational creation of two-component conjugated polymer systems with high levels of phase purity in each component is challenging but crucial for realizing printed soft-matter electronics. Here, we report a mixed-flow microfluidic printing (MFMP) approach for two-component π -polymer systems that significantly elevates phase purity in bulk-heterojunction solar cells and thin-film transistors. MFMP integrates laminar and extensional flows using a specially microstructured shear blade, designed with fluid flow simulation tools to tune the flow patterns and induce shear, stretch, and pushout effects. This optimizes polymer conformation and semiconducting blend order as assessed by atomic force microscopy (AFM), transmission electron microscopy (TEM), grazing incidence wide-angle X-ray scattering (GIWAXS), resonant soft X-ray scattering (R-SoXS), photovoltaic response, and field effect mobility. For printed all-polymer (poly[(5,6-difluoro-2-octyl-2H-benzotriazole-4,7-diyl)-2,5-thiophenediyl[4,8-bis[5-(2-hexyldecyl)-2-thienyl]benzo[1,2-b:4,5-b′]dithiophene-2,6-diyl]-2,5-thiophenediyl]) [J51]:(poly{[N,N′-bis(2-octyldodecyl)naphthalene-1,4,5,8-bis(dicarboximide)-2,6-diyl]-alt-5,5′-(2,2′-bithiophene)}) [N2200]) solar cells, this approach enhances short-circuit currents and fill factors, with power conversion efficiency increasing from 5.20% for conventional blade coating to 7.80% for MFMP. Moreover, the performance of mixed polymer ambipolar [poly(3-hexylthiophene-2,5-diyl) (P3HT):N2200] and semiconducting:insulating polymer unipolar (N2200:polystyrene) transistors is similarly enhanced, underscoring versatility for two-component π -polymer systems. Mixed-flow designs offer modalities for achieving high-performance organic optoelectronics via innovative printing methodologies.

42 ENGINEERING↗

DOE OSTI2021

Progress on Computational Modeling of Water-Based NSTF (FY2021)

This report documents the FY21 progress and achievements made in the computational analyses of the water-based NSTF. Both system-level and high-fidelity Computational Fluid Dynamics (CFD) analyses were performed to gain a complete understanding of the complex flow and heat transfer phenomena in natural convection systems. The progress on the waterbased NSTF experimental testing is summarized in a companion report (ANL-ART-230). As a continuation of progress from previous years, in FY21 the RELAP5 model of the NSTF was first updated to include a representative heated cavity that incorporated convection and conduction means of heat transfer. Two different cavity models were developed, one that models the radiation heat exchange among all surfaces in one enclosure (Cavity Model 1), and another that employs multiple radiation enclosures with each considering the surfaces at one axial level (Cavity Model 2). This updated RELAP5 deck was benchmarked with single-phase test data to tune form loss coefficients of the elbows and tees, along with heat transfer coefficients within the cavity and off the external insulation panels. This tuned model was then found to accurately predict fluid temperatures within 2.5% and both system and riser flow rates within 6% during single-phase, steady-state simulations. For transient simulations, there is a slight over prediction of the flow rate, fluid temperatures, and heater temperatures during the heat-up period, which indicate that the transient heat loss may be underestimated. Following, the capabilities of RELAP5-3D were examined, which feature a conduction enclosure model that is not present in the current version of RELAP5-MOD3.3 used for all previous NSTF simulations. As an initial comparison of the two codes, single-phase simulations were run that used similar input decks. The results indicate that the single-phase flow predicted by the two codes was very similar, however RELAP5-3D appears to predict a higher system flow during the two-phase transient when compared to the flow rates predicted by RELAP5-MOD3.3. Furthermore, RELAP5-3D run did not capture the density wave oscillations or geysering phenomena, which are large oscillation flow instabilities observed in the experimental facility. To further the prediction capabilities for capturing two-phase instabilities, Options 55, 57, 58, 61, which are implemented by default in RELAP5-MOD3.3 but not in RELAP5-3D, were investigated. When enabling Option 61, RELAP5-3D agrees well with MOD3.3 in predicting the total system flow, while other options have negligible effect on the predicted total system flow by RELAP5-3D. However, none of these options enables RELAP5-3D to produce the same flow instabilities. For future steps, efforts are currently underway to investigate RELAP5-3D’s different behavior in predicting low-pressure two-phase instabilities. STAR-CCM+ was used to perform CFD analysis of the water-based test facility and provide simulation results for comparisons to experimental data. Efforts first focused on describing the characteristics of flow within the heated cavity. A study was performed on whether possible leakage flow between the two sides of the cavity could substantially impact and explain the results. An additional second assumption was examined which defined adiabatic side walls, so physical insulation structures were added to the models to allow conduction across this outer insulation. The results suggest that potential porosity of the insulation could be a major factor in the temperature distribution within the cavity and should be considered in any studies where it is desirable to know the cavity wall temperatures to higher accuracy.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2018

Fully coupled wellbore-reservoir simulation of supercritical CO 2 injection from fossil fuel power plant for heat mining from geothermal reservoirs

The concept of injecting supercritical CO 2 (sCO 2 ) into a geothermal reservoir was computationally investigated to assess its performance in terms of the benefit of using CO 2 captured from fossil power plants for geothermal heat mining. A coupled wellbore-reservoir system was simulated considering the flow of pure sCO 2 in an injection well, the interaction of sCO 2 and water in a permeable reservoir, and the flow of the two-phase mixture of sCO 2 and water in a production well. Results of simulations indicate that this CO 2 application is capable of providing a good source of renewable energy. It was found that for a reservoir with a 0.08 km 3 volume, about 8-9 MW th could be extracted in a steady state fashion for a 30-year lifetime operation. This is approximately equivalent to 100 MW th /km 3 . A sensitivity analysis provided information on the impact of certain parameters on the performance of the integrated system. The injection flowrate, the distance between the production and injection wellbores and the penetrating depth of the production wellbore into the reservoir have a first order impact on the pressure management of the reservoir. Additionally, CO 2 injection temperature has a large effect on the thermosiphon characteristics of the system.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2022

Dynamic Modeling, Parameter Estimation, and Data Reconciliation of a Supercritical Pulverized Coal-Fired Boiler

A high-fidelity, spatially distributed dynamic model of a supercritical pulverized coal-fired boiler was developed for calculating transient thermal profiles of the boiler tubes, which are often not measured or unmeasurable in industrial settings due to the harsh operating conditions. In this work, rigorous models of the subcritical and supercritical steam properties, which can be highly nonlinear, were used to capture the transition between two-phase and one-phase flow, respectively, as supercritical boilers frequently transition through the critical point during load-following operation. The transient boiler model was also used for data reconciliation and parameter estimation for the purpose of model validation against industrial data. An approach was developed to reduce the size of large-scale reconciliation problem by focusing on the implementation of bias terms for the reconciled variables, which can be estimated in place of the reconciled variables themselves. In addition, a functional approximation of the reconciliation problem was defined so that it can be more simply optimized. Combining this functional approximation optimization with reformulation of the reconciliation problem considering measurement biases can significantly improve the tractability of many such large-scale problems. The validated boiler model was then used to study transient responses under load-following operation with specific attention on the calculation of unmeasurable variables.

42 ENGINEERING↗

DOE OSTI2023

Improved Water Sound Synthesis using Coupled Bubbles

We introduce a practical framework for synthesizing bubble-based water sounds that captures the rich inter-bubble coupling effects responsible for low-frequency acoustic emissions from bubble clouds. We propose coupled-bubble oscillator models with regularized singularities, and techniques to reduce the computational cost of time stepping with dense, time-varying mass matrices. Airborne acoustic emissions are estimated using finite-difference time-domain (FDTD) methods. We propose a simple, analytical surface-acceleration model, and a sample-and-hold GPU wavesolver that is simple and faster than prior CPU wavesolvers. Sound synthesis results are demonstrated using bubbly flows from incompressible, two-phase simulations, as well as procedurally generated examples using single-phase FLIP fluid animations. Our results demonstrate sound simulations with hundreds of thousands of bubbles, and perceptually significant frequency transformations with fuller low-frequency content.

Computer Science↗