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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 OSTI2022

Optimized Test Section for Helium Flow Loop Experiment

Phase 3 of this project uses the knowledge and techniques gained from Phase 1 and Phase 2. The first outcome of Phase 3 is a new test section which can be manufactured and tested in the Helium Flow Loop Experiment to verify the results of the optimization study. The second outcome of Phase 3 is analyzing the features of this design and determining its performance under simulated TBM conditions: heat flux, pressure, mass flow rate, one-sided and volumetric heating. This will be accomplished by first using the results from the Phase 1 analyses and then applying the optimization strategy from Phase This phase uses the STAR-CCM+ Design Manager tool to apply the optimization strategy to the Helium Flow Loop Experiment (HFLE). The optimization algorithm used by the Design Manager tool is Simultaneous Hybrid Exploration that is Robust, Progressive, and Adaptive (SHERPA search algorithm). In addition to demonstrating the optimization features, a simple parameter sweep is also included in this phase. This report details the applied single objective optimization.

42 ENGINEERING↗

DOE OSTI2025

Experimental and Computational Characterization of a Modified Sioutas Cascade Impactor for Respirable Radioactive Aerosols

Oak Ridge National Laboratory is collecting and characterizing aerosols released when spent nuclear fuel (SNF) rods are fractured in bending. An aerosol collection system was designed and tested to collect respirable sized (<10 μm aerodynamic diameter [AED]) particulates inside a hot cell facility. The setup is a modified version of the commercially available Sioutas cascade impactor, to which additional stages were added to expand the aerosol collection range from 2.5 to ~15 μm AED. To accommodate the additional stages and specific test conditions, the operating flow rate for aerosol collection was reduced, and testing was conducted by using pressure drop measurements, surrogate dust collection, and particle size characterization. The fluid flow distribution within the cascade and its stages was simulated in STAR-CCM+, and the stage-wise pressure drops obtained using the computational fluid dynamics model were then compared to experimental data. Lagrangian particle simulations were also performed, and stage-wise collection statistics were obtained from the simulation for comparison with the experimental data obtained using SNF-surrogate dust particles. The results provide valuable insights into the stage-wise particle collection characteristics of the modified cascade impactor and can also be used to improve the prediction accuracy of the manufacturer-determined analytical correlations.

aerosol modeling↗

DOE OSTI2024

Empirical Dynamic Modeling Reveals Complexity of Methane Fluxes in a Temperate Salt Marsh

Abstract Methane dynamics within salt marshes are complex because vegetation types, temperature, oscillating water levels, and changes in salinity and redox conditions influence CH 4 production, consumption, oxidation, and emissions. These non‐linear and complex interactions among variables affect the traditionally expected functional relationships and present challenges for interpreting and developing process‐based models. We employed empirical dynamic modeling (EDM) and convergent cross mapping (CCM) as a novel approach for characterizing seasonal/multiday and diurnal CH 4 dynamics by inferring causal variables, lags, and interconnections among multiple biophysical variables within a temperate salt marsh using 5 years of eddy covariance data. EDM/CCM is a nonparametric approach capable of quantifying the coupling between variables while determining time scales where variable interactions are the most relevant. We found that gross primary productivity, tidal creek dissolved oxygen, and temperature were important for seasonal/multiday dynamics (rho = 0.73–0.80), while water level was most important for diurnal dynamics during both the growing and dormancy phenoperiods (rho = 0.72 and 0.56, respectively). Lags for the top‐ranked variables (i.e., gross primary productivity, dissolved oxygen, temperature, water level) occurred between 1 and 5 weeks at the seasonal scale and 1–24 hr at the diurnal scale. The EDM had high prediction capabilities for intra‐/inter‐seasonal patterns and annual CH 4 sums but had limitations in representing large, infrequent fluxes. Results highlight the importance of non‐linearity, drivers, lag times, and interconnections among multiple biophysical variables that regulate CH 4 fluxes in tidal wetlands. This research introduces a novel approach to examining CH 4 fluxes, which will aid in evaluating current paradigms in wetlands and other ecosystems.

Environmental Sciences & Ecology↗

DOE OSTI2024

Final Report: Enhanced Algal Production of CA for Improved Atmospheric Delivery of CO2 To Ponds

Technologies that enable direct-air-capture (DAC) of CO2 and eliminate the need for a CO2 capture, storage, and distribution system would significantly reduce the cost of algal production, and greatly increase the volume of algae biomass that can be produced by enabling algae farms to be located anywhere. Such technologies include cultivation under high alkalinity/high pH conditions, which increase the driving force for CO2 absorption, and development of genetic tools and genetically engineered strains to decorate the surface of the algae with carbonic anhydrase (CA), enable secretion of CA by the algae, or more generally boost the performance of the carbon concentrating mechanism (CCM).

09 BIOMASS FUELS↗

DOE OSTI2022

Crucible Melter Simulation in Nek5000

Nuclear tank waste at the Hanford site is slated for vitrification in large scale refractory-lined melters to transform it into a stable borosilicate waste form suitable for long-term storage or disposal. Molten glass corrodes the refractory lining over time at a rate correlated to the velocity of molten glass against the refractory-lined wall. To properly design a melter and plan for maintenance, it is necessary to accurately model the glass flow and find the correlation between flow velocity and corrosion rate. This modeling was started in STAR-CCM+ CFD software and is being continued in Nek5000 for its fast-running and quick turnaround code. This poster explains the basic process of reconstructing the geometry, fluid properties, and heating of test melters in Nek5000. The geometry is imported from a mesh file and boundary conditions assigned based on surface IDs. The fluid properties are set in the .par and .usr case files. The heating of the actual crucibles in joule heating with electrodes but simulated in Nek5000 with a volumetric heat source term. This volumetric heat source is fit to the actual heating profile with piecewise polynomials and exponentials. Basic results and verification methods are explained in the poster, as well as further work that must be done to complete modeling.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

Multi-Physics Investigation of a Natural Circulation Molten Salt Micro-Reactor that Utilizes an Experimental In-Pile Device to Improve Core Physics and System Thermal-Hydraulic Performance.

INL employee PhD Dissertation - The Molten Salt Reactor (MSR) concept is a rapidly evolving Generation IV design that has recently attracted favorable attention due to the potential for reducing waste generation, realizing passive safety features, and seizing on the opportunity for cost effective economics. This thesis investigates the performance benefit of a new device invented by the doctoral candidate. The device is referred to as a Wrapped Helix around an Inclined Plane or WHIP. The WHIP is protected under a provisional patent filed with the USA Patent Office on 28 September 2021 under application number 63/261,776, BEA docket number BA-1254. The WHIP device can be located in-core or near-core to promoted enhanced thermal-hydraulics and neutronics performance. While the WHIP can be employed in a variety of solid or liquid fuel designs, this thesis investigates the device’s benefit in the application of a natural-circulation, micro-molten salt nuclear battery concept (MsNB). This thesis will specifically investigate the temperature coefficient of the MsNB fuel (FLiNaK) using novel temperature sensitivity techniques unique to Serpent particle transport code, evaluate the WHIP’s thermal-hydraulic and neutronic performance effects using both established (STAR-CCM+) and novel (Python code developed to estimate the circulation effective delayed neutron fraction, ßef f ) analytical and numerical methods, evaluate the neutron noise behavior of the MsNB and how the WHIP may alter the character of the MsNB’s transfer function, and how the WHIP affects the autonomous, load-following performance under transient power conditions using Python code developed by the candidate. The sum body of this work, in part, has been published in three journal articles as the timing of the provisional patent process has allowed. Results show that creative utilization of WHIP engineering design and function reduces reactor system volume, fuel loading, control/stability in the buoyant regime

buoyant flow↗

DOE OSTI2021

Effects of Ink Formulation on the Structure and Performance of PGM-Free Catalyst Layer in PEMFCs

Platinum group metal (PGM) catalysts are the major electrocatalysts for oxygen reduction reaction (ORR) in the polymer electrolyte membrane fuel cells (PEMFCs). The cost becomes unaffordable if the PEMFC is in massive application. The PGM-Free catalyst shows very promising activity in rotation disk electrode (RDE) testing. The half-wave potential could reach 0.91 V versus standard hydrogen electrode (SHE). However, in a membrane electrode assembly (MEA), the performance of PGM-Free catalysts is not good enough to replace the PGM catalysts. Since the PGM-free catalysts are so different from the PGM catalysts in terms of catalytic activity, stability, surface conditions, particle size, etc., the fabrication of PGM-Free catalyst MEA cannot simply copy the method of making PGM MEA. Here we proposed a novel method of fabricating PGM-Free catalyst MEA, so that the intrinsic catalyst activity from RDE can be translated into MEA performance. The method is based on the catalyst coated membrane (CCM) method using optimized ionomer to carbon (I/C) ratio and solvent mixture of catalyst ink. Using this method, the PGM-free catalyst MEA achieved the current density 44.9 mA cm -2 at 0.9 V iR-free in H 2 /O 2 and 150 mA cm -2 at 0.8 V in H 2 /air, which surpassed the performance targets of US Department of Energy (DOE)for PGM-Free catalyst MEA. The property (solvent composition, dispersion of catalyst and ionomer in an ink), structure (pore structure) and the MEA performance have been characterized using, mercury intrusion porosimetry (MIP), MEA testing. A property-structure-performance relationship has been established.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2022

Modeling Framework to Analyze Performance and Structural Reliability of Solid Oxide Electrolysis Cells

Solid oxide electrolysis cells (SOEC) have been receiving significant attention recently because of their high energy efficiency and fast hydrogen production. In this study a multi-physics model to simulate the SOEC performance and structural reliability of a state-of-the-art planar SOEC design was developed. The electrochemical reactions, fluid dynamics, species transport, electron transfer, and heat transfer were modeled in the commercial computational fluid dynamics (CFD) software STAR-CCM+. The thermomechanical analysis and the associated structural reliability evaluations were conducted using the commercial finite element analysis software ANSYS. The electrochemistry model was validated by using the experimentally obtained current-voltage (I-V) characteristics of the electrode-supported SOECs. The reliability analysis using a risk-of-rupture approach showed low failure probabilities under standard operating conditions considered in this study. For cells operated at voltages well above a thermoneutral voltage, the reliability evaluations indicated a potential risk of cell failure, but the damage was concentrated locally in specific areas of the cell which typically do not lead to total loss of cell function. The presented approach provides insights for evaluating representative cell and stack performances and structural reliability without intensive testing and for developing optimally performing and structurally reliable SOECs for efficient hydrogen generation.

25 ENERGY STORAGE↗

NASA NTRS2019

Establishing Best Practices for X-57 Maxwell CFD Database Generation

The X-57 Maxwell is NASA’s latest electric airplane concept that has been simulated for aerodynamic performance using the structured overset and unstructured grid solvers within the Launch Ascent and Vehicle Aerodynamics (LAVA) solver framework as well as the unstructured polyhedral grid solver in Star-CCM+ for code-to-code comparison. In order to validate the predictions, comparisons were made between the CFD solutions and experimental data collected in the 12-foot Low-Speed Wind Tunnel at NASA Langley Research Center. The simulations are in preparation for the development of a comprehensive aerodynamic database which will assess aircraft performance at a variety of conditions. The findings from these simulations will establish the best practices for mesh resolution, numerical discretization, and turbulence modeling to be used for this database. Preliminary database results have shown that best-practices learned from the initial validation simulations will potentially reduce error in X-57 aerodynamic loads and moments relative to experiment by up to 14%.

Duensing, Jared C.↗

NASA NTRS2018

Surface Deposition of Molecular Contaminants in the Mars 2020 Rover Wake

The Mars 2020 rover has very strict contamination control requirements in order to prepare samples for a potential Mars Sample Return. It is known that the rover will out gas a low-level of molecular contaminant on the surface of Mars, and numerical simulations using STAR-CCM+ are performed in order to predict the magnitude of the contaminant deposition to the Martian surface in the vicinity of the rover. This is done in order to determine whether or not the M2020 rover could self-contaminate a potential sampling site if it were to remain in the same location for a long period of time. Simulations are performed under a variety of surface conditions, and it is determined that the predicted level of molecular contaminant deposition to the surface near the rover will not be a signiﬁcant factor in the overall sample contamination budget.

Katz, Ira↗

NASA NTRS2000

Climatology of the Finite-Volume CCM and Sensitivity Studies

A new model has been developed in the Data Assimilation Office at NASA Goddard Space Flight Center. It is intended for data assimilation and general circulation modeling, including representations of radiatively active trace gases such as stratospheric ozone. The model is based on the flux-form semi-Lagrangian' dynamical core, developed by Lin and Rood. In collaboration with the National Center for Atmospheric Research, the physical parametrization package from the Community Climate model, Version 3, has been included. This paper will discuss the climatology of a multi-year integration of the model, with observed boundary conditions (sea-surface temperature, sea ice, and incoming solar radiation). The standard model version has a resolution of 2.5 degrees longitude, 2 degrees latitude and has 55 levels between the surface and 80km. The mean climate and interannual variability of this model will be discussed, with emphasis on the middle atmosphere. The sensitivity to horizontal resolution will be examined, as will the impact of increasing and decreasing the vertical resolution. Changes which differ significantly from the interannual variations of the control run will be highlighted. Impacts of using long-term mean boundary conditions or values which vary from year to year will be discussed. Changes in the tropospheric circulation induced by lowering the upper boundary of the model will be discussed. The emphasis of the paper is on the climatology of the middle atmosphere and its impacts on the troposphere, with particular attention given to the climatologically important region near the tropopause.

Pawson, Steven↗

DOE OSTI2021

Limitation of C4 photosynthesis by low carbonic anhydrase activity increases with temperature but does not influence mesophyll CO2 conductance

The CO2-concentrating mechanism (CCM) in C4 plants is initiated by the uptake of bicarbonate (HCO3…) via phosphoenolpyruvate carboxylase (PEPC). Generation of HCO3– for PEPC is determined by the interaction between mesophyll CO2 conductance and the hydration of CO2 to HCO3– by carbonic anhydrase (CA). Genetic reduction of CA was previously shown not to limit C4 photosynthesis under ambient atmospheric partial pressures of CO2 (pCO2). However, CA activity varies widely across C4 species and it is unknown if there are specific environmental conditions (e.g. high temperature) where CA may limit HCO3– production for C4 photosynthesis. Additionally, CA activity has been suggested to influence mesophyll conductance, but this has not been experimentally tested. We hypothesize that CA activity can limit PEPC at high temperatures, particularly at low pCO2, but does not directly influence gm. Here we tested the influence of genetically reduced CA activity on photosynthesis and gm in the C4 plant Zea mays under a range of pCO2 and temperatures. Reduced CA activity limited HCO3– production for C4 photosynthesis at low pCO2 as temperatures increased, but did not influence mesophyll conductance. Therefore, high leaf CA activity may enhance C4 photosynthesis under high temperature when stomatal conductance restricts the availability of atmospheric CO2.

Plant Sciences↗

DOE OSTI2021

TRANSIENT THERMAL MODELING OF THE HIGH BURNUP DEMONSTRATION RESEARCH PROJECT CASK USING STAR-CCM+ AND COBRA-SFS

The Department of Energy in collaboration with the Electric Power Research Institute is in the process of conducting the High Burnup Demonstration Project. Where the objective is to characterize the performance of high-burnup fuel in long term storage. As part of this demonstration, a TN-32B dry storage cask was instrumented and loaded with spent nuclear fuel at North Anna Nuclear Generating Station in November 2017. The project cask provides a unique opportunity to gain information on spent fuel and cask performance from an in-service operational system. The cask was instrumented with thermocouples inside of the fuel assemblies, then loaded and dried using normal procedures. After the drying process a thermal soak period where the cask was left indoors was used to obtain steady temperatures for model comparison along with surface temperatures. This paper details thermal modeling validation work that was done to model both the steady state and transient cases. Two modeling tools were used to predict temperatures in the cask. The general purpose CFD and heat transfer code STAR-CCM+ was used with both a detailed pin-by-pin model was used along with a more efficient k-effective simplification. The other code is COBRA-SFS, a purpose-built detailed thermal modeling tool developed and maintained at PNNL. Results from all the modeling tools were compared blind to the test data. Each model utilized general design information and compared reasonably well to the blind steady state data using convection and surface temperature boundary conditions. Post-test adjustments were later made to better reflect the “as built” conditions of the cask. Based on lessons learned from the steady state analysis the vacuum drying process was modeled in both codes. Utilizing the measured loading conditions the transient models were able to compare very well with the measured data. Overall the project showed an ability to model spent fuel storage conditions very well and future work is planned to generalize the methodology used for vacuum drying.

Thermal Analysis, Spent Fuel, Dry Storage↗

DOE OSTI2020

In-situ and in-operando analysis of voltage losses using sense wires for proton exchange membrane water electrolyzers

Proton exchange membrane water electrolyzer development requires understanding processes at the materials and interface levels to reach the required performance and lifetime targets for increasing market penetration. To achieve the required progress, it is critical to develop advanced in-situ diagnostics that allow observation of the changes that come with the reduction of catalyst loading combined with long-term intermittent operation. This work presents an internal voltage sensing method that enables observing internal voltage drops in an operating electrolyzer cell. It allows the total cell resistance to be separated into anode, CCM, and cathode resistance. The method is demonstrated by operating cells with different anode porous transport layers (PTLs). The changing properties of the PTLs result in significant variations of the resistances. Enhancing the PTL properties with a protective coating reduces the anode resistance significantly. In addition to these observations, the method enables a real-time monitoring of resistance related values that impact performance in water electrolyzers. Long-term experiments with the method allow us to gain insights into processes that occur during operation such as conditioning or degradation. The internal voltage sensing method presented in this study is a novel technique for diagnosing, analyzing, and optimizing water electrolyzers and other energy conversion devices.

42 ENGINEERING↗

NASA NTRS2011

Evaluation of Convective Transport in the GEOS-5 Chemistry and Climate Model

The NASA Goddard Earth Observing System (GEOS-5) Chemistry and Climate Model (CCM) consists of a global atmospheric general circulation model and the combined stratospheric and tropospheric chemistry package from the NASA Global Modeling Initiative (GMI) chemical transport model. The subgrid process of convective tracer transport is represented through the Relaxed Arakawa-Schubert parameterization in the GEOS-5 CCM. However, substantial uncertainty for tracer transport is associated with this parameterization, as is the case with all global and regional models. We have designed a project to comprehensively evaluate this parameterization from the point of view of tracer transport, and determine the most appropriate improvements that can be made to the GEOS-5 convection algorithm, allowing improvement in our understanding of the role of convective processes in determining atmospheric composition. We first simulate tracer transport in individual observed convective events with a cloud-resolving model (WRF). Initial condition tracer profiles (CO, CO2, O3) are constructed from aircraft data collected in undisturbed air, and the simulations are evaluated using aircraft data taken in the convective anvils. A single-column (SCM) version of the GEOS-5 GCM with online tracers is then run for the same convective events. SCM output is evaluated based on averaged tracer fields from the cloud-resolving model. Sensitivity simulations with adjusted parameters will be run in the SCM to determine improvements in the representation of convective transport. The focus of the work to date is on tropical continental convective events from the African Monsoon Multidisciplinary Analyses (AMMA) field mission in August 2006 that were extensively sampled by multiple research aircraft.

Pickering, Kenneth E.↗

DOE OSTI2022

Convective heat transfer and friction factor characteristics of molten salts in spirally fluted tubes

Spirally fluted tubes have been widely used for heat exchangers due to their superior heat transfer enhancement. However, most of the previous studies focused on the effects of a limited number of geometric parameters, i.e., the flute pitch and flute depth, on convective heat transfer and friction factor characteristics of low-Prandtl-number fluids, i.e., air and water. The correlations developed in these studies may not be accurate or applicable for medium-Prandtl-number fluids, such as molten salts. A numerical analysis using a Computational Fluid Dynamics (CFD) tool, STAR–CCM+, is therefore carried out in this study to systematically investigate the effects of four geometric parameters, including the flute pitch ρ, flute depth e, flute start number N s (or flute helix angle θ), and trough length L tr on convective heat transfer and friction factor characteristics of a medium-Prandtl-number fluid, FLiNaK (46.5LiF-11.5NaF-42KF mol %), in spirally fluted tubes. Additionally, the convective heat transfer and Darcy friction factor correlations are proposed and validated, with ± 20% uncertainties, for medium-Prandtl-number fluids under the following conditions: Re = 88–1600, Pr = 2.5–40, ρ/D c = 0.44–3.51, e/D c = 0.10–0.40, θ/90= 0.20–0.81, and L tr /D c = 0.71–2.16. The correlations proposed help improve the design of spirally fluted-tube heat exchangers.

42 ENGINEERING↗

DOE OSTI2024

THERMAL MODELING OF HANFORD CESIUM AND STRONTIUM CANISTERS DURING SIMULATED LOADING

A computational fluid dynamics (CFD) model was built to simulate planned testing of heater assemblies within a canister and overpack for the Hanford Lead Canister (HLC) project. The HLC is a canister storage system that will contain heaters to simulate the decay heat of nuclear material and provide the canister storage system with environmental conditions equivalent to the operating conditions on a dry storage pad. The HLC will be equipped with long-term data collection and monitoring systems to provide an early warning of corrosion, pitting, cracking, or other signs of canister degradation that might threaten the integrity of the containment boundary over the potentially long term of dry storage. An important part of the HLC development is to make pretest numerical predictions for the behavior of the heated canister during the simulated radiolytic decay heat testing, which simulates the dry storage system during loading operations. The simulated radiolytic decay heat test is planned for mid-2024 in a configuration that includes the heater assembly, overpack, and canister, but with the lids removed to allow loading cesium and strontium capsules into the canister. One of the goals of the test is to evaluate the thermal behavior of the canister and overpack assembly in the ambient air of the test facility, which will provide data critical to validating the thermal models and understanding how the HLC will perform as a system once deployed. To best approximate real-world conditions, the CFD model includes the full air volume of the mock-up truck bay the heated canister test will be performed in, enabling detailed investigation of how the heated canister affects airflow around it. Rigorous pre-deployment testing of the complete HLC cask and canister system is intended to be completed before the HLC is deployed in the 2028 timeframe. This study presents the pre-test temperature predictions of the simulated radiolytic decay heat test. A description of the heater assembly, canister, and overpack system is presented. The model was developed with the commercial CFD software STAR-CCM+. An uncertainty analysis was run with the CFD model to determine the uncertainty in the temperature predictions and provide a range over which the predicted temperatures are expected to vary. The uncertainty analysis was preformed by coupling STAR-CCM+ with the software Dakota, which provides advanced parametric analyses, including quantification of margins and uncertainty with computational models. This work is expected to provide insight into SNF canister behavior.

Carpenter-Graffy, Dina E.↗