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DOE OSTI2021

System Configuration Evaluation for Process Settling of Hanford Waste Solid Particles

Direct Feed High-Level Waste (DFHLW) is a potential flowsheet operations approach to initiating high-level waste (HLW) vitrification prior to completion of the Hanford Waste Treatment and Immobilization Plant (WTP) Pretreatment Facility. A settle/decant process has been proposed to concentrate solids prior to delivery to the WTP HLW Facility during DFHLW operations, wherein the solids in a settled layer would be remixed with the supernatant liquid remaining after decanting operations to provide the feed at required solids concentrations. Settling would be used in lieu of purpose-built filtration or other solids separation equipment. Pacific Northwest National Laboratory (PNNL) is providing baseline technical support to the Washington River Protection Solutions (WRPS) Flowsheet Integration group. To support planning for DFHLW, WRPS previously requested that PNNL evaluate the current data set available to predict the time needed for HLW solids to settle and the solids concentration and strength of that settled layer, to identify gaps in the understanding and predictive capability of HLW solids waste settling times, and to provide scoping estimates of the potential settling times. Eight technical gaps were identified for predicting settling times and characteristics of the formed sediment layers. In addition to the data gaps, an overarching observation was made that there is significant variation in behavior of settling rate and settled layer data. The settling time required to concentrate solids via a settle/decant process was determined from the limited data to have a difference of potentially more than a factor of 5,000 in the estimated settling times, varying from 0.2 to 1,060 days for example depending on process vessel depth and final sediment solids concentration. In contrast, successful processes of liquid-forward output streams resulting from in-tank settling and decanting forward liquid have been reported for operations conducted at the Hanford Site. The purpose of this current report is to further support DFHLW planning by evaluating double-shell tank (DST) and alternate vessel equipment and operational configurations to enable optimization of the settle/decant process to concentrate solids. Hanford waste processing behavior specific to liquid feed availability following a slurry transfer in a DST is summarized, including process stream characteristics and process equipment configurations. The performance of DST process equipment configurations is evaluated for possible improvements using computational fluid dynamics (CFD) and simple analytical models. Potential new vessel design(s) specific to enabling effective settle/decant processes, and cursory summary of other separate and inline solids separations processes, are also provided. The CFD results indicated that improvement in outflow solids concentration was promoted by a reduction in the slurry flow rate, angling the distributor nozzles downward, and lifting the transfer pump. The solid-liquid analysis evaluating particle trajectory confirmed that the potential for particle ingestion (in the transfer pump) was decreased with increased radial separation between the inlet and outlet (transfer pump inlet), decreased inlet flow, and decreased liquid density and viscosity for a neutrally buoyant inlet flow. An assessment was also made of the potential for inflow configuration changes to result in the discrete mounding or piling of solids within the tank. Based on the characterization of the settled waste to date, HLW sediments will be unlikely to sustain a substantial angle of repose to facilitate significant variations in the elevation of the settled solids.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2023

Development of a 300 MWe Utility Scale Oxy-Fuel sCO2 Turbine

A 300 MWe direct-fired supercritical carbon dioxide (sCO2) oxy-fuel turbine is being developed that will burn natural gas-fired, coal syngas and even hydrogen mixtures capable of 1,150ºC turbine inlet temperature at 300 bar. This design will significantly improve the state-of-the-art for thermal efficiency and results in a high-pressure stream of CO2 with 98%+ carbon capture, making the power plant near emission-free and more efficient than Natural Gas Combined Cycle (NGCC) plants with carbon capture. This power plant will be capable of burning coal through gasification and cleanup of the synthesis gas (syngas). sCO2 power cycles are a transformational technology for the energy industry, providing higher efficiency heat source energy conversion for conventional and alternative energy sources. This novel cycle significantly reduces capital costs because of smaller equipment footprints, design modularity, and allows for rapid cyclic load and source following to balance solar and wind energy power swings. Oxy-fuel sCO2 cycles take these advantages even further, utilizing higher firing temperatures, improved efficiency, and simpler carbon capture strategies. This turbine will require cooled turbine nozzles and blades as well as advanced thermal management systems to accommodate these high temperatures. The cooled blade heat transfer correlations required new test programs at higher Reynolds number than air-breathing gas turbines for impingement, serpentine, and pin-fin regions. Novel blade optimization was performed to maximize aerodynamic efficiency, while minimizing cooling flows. A turbine layout was generated utilizing individual combustor cans with cooled liners feeding into a 6-stage axial flow turbine with cooled stator nozzles and turbine blades. The case design and thermal management preliminary design will be described.

Moore, Jeffrey↗

DOE OSTI2022

Method and apparatus for desalinating water

This disclosure concerns a system and a method for removing dissolved solids from liquids. Specific implementations concern desalinating water. The system may comprise a blower, such as a thermal fan/compressor, configured to atomize a solid-bearing liquid to produce a hot, humid gas containing dissolved solids; a gas-solid separator configured to receive hot, humid gas containing entrained dissolved solids from the blower to separate the solids from the humid gas and to transmit the humid gas with solids removed through an exit port; a heater configured to heat the hot, humid gas received from the exit port of the gas-solid separator; and a condenser configured to receive heated humid gas from the heater and to condense solids-free liquid therefrom. The thermal fan/compressor may comprise a plurality of nozzles with outlets positioned adjacent atomization apertures across which a solid-bearing liquid flows and through which gas exiting the nozzles passes.

Abbasi, Bahman↗

DOE OSTI2023

Method and apparatus for desalinating water

Abbasi, Bahman↗

DOE OSTI2020

Operation and turndown of a segmented annular combustion system

The present disclosure is directed to the operation and turndown of a segmented annular combustion system. The method includes injecting, via a fuel nozzle, a combustible mixture into a primary combustion zone between an adjacent pair of integrated combustor nozzles and burning the combustible mixture. The method further includes flowing air and injecting fuel into a premixing channel defined within a first integrated combustor nozzle to produce a second combustible mixture. The second combustible mixture is injected into a secondary combustion zone where it is combusted. The flow of combustion gases is accelerated, via turbine nozzles of the integrated combustor nozzles, toward turbine blades of a downstream turbine section. The method permits turndown of the combustion system by reducing or shutting off fuel to various components of the combustion system.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2024

High Temperature Additive Architectures for 65% Efficiency (Final Technical Report)

This project aimed to develop advanced high-temperature additive components that contribute towards the DOE’s goal for advanced gas turbines that are capable of at least 65% efficiency in combined cycle application. The objective was to leverage state-of-the-art additive manufacturing to develop an innovative stage 1 turbine nozzle (S1N) that can provide cooling flow savings while maintaining the component durability expected in today’s gas turbines. The program had two phases. Phase I was a conceptual phase for novel advanced cooling designs enabled by additive manufacturing, as well as proposals for validation. Phase II included execution of the Phase I conceptual design, including manufacturing of prototype hardware and validation within an environment that is similar to engine operation. During Phase I of the program, the team devised a concept to reduce cooling air usage. The cooling air used in the side walls is filmed out along the side walls, while the cooling air used in the airfoil is eventually directed to near-wall channels and exits holes along the airfoil trailing end. During this program, the team performed additive trials to analyze the geometric limitations of additive manufacturing. This helped the team understand minimum wall thicknesses, hole sizes, and cooling channel dimensions among other limits. Phase II of this program pushed GE Vernova beyond its previous experience of designing and manufacturing an additively manufactured hot gas path component. Modern hot gas path components utilize material chemistries that are traditionally hard to weld, such as cast Renè 108, and exhibit solidification cracking when additively manufactured using Direct Metal Laser Melting (DMLM). Note that AM108 is a powder form of Renè 108. A S1N with advanced cooling is larger and more complex than parts previously built by additive manufacturing and required new learnings to resolve risks around solidification cracking. Finally, the team validated the design in a combustion rig that replicated operation in a gas turbine. In order to properly quantify the benefits of the new additive design, a baseline was also tested in the rig and operated under the same conditions. In addition, an uncertainty analysis was done to quantify any sources of error that could impact the results. At the end of the validation effort, it was determined that the additive nozzle exceeded the 15% reduction in cooling flow goal even with the worst-case assumptions for uncertainty.

03 NATURAL GAS↗

DOE OSTI2020

Segmented annular combustion system

An annular combustion system includes a fuel nozzle, a panel fuel injector including a fuel plenum and at least one premixing channel therein, an inner liner including an inner band radially spaced from an outer band and an inner flow annulus formed therebetween, and an outer liner radially spaced from the inner liner and comprising an inner band radially spaced from an outer band and an outer flow annulus formed therebetween. The fuel nozzle is positioned radially between the inner liner and the outer liner, and the panel fuel injector extends radially between the inner liner and the outer liner. At least one of the inner flow passage and the outer flow passage is in fluid communication with at least one of a premix air plenum, a cooling air cavity and a cooling air plenum defined within the panel fuel injector.

42 ENGINEERING↗

DOE OSTI2025

Fuel cells for single-aisle regional aircraft: System configuration, performance and cost

A hydrogen fuel cell propelled electric aircraft can compete with incumbent turbofan technologies for single-aisle regional aircraft by coupling design of stack, air handling, thermal management, propulsion, and airframe to optimize performance. The stack operates at 95°C to facilitate heat rejection during take-off and below 75°C during cruise to extend lifetime and is oversized to satisfy power requirements at end of life. A multi-stage turbocompressor with a compression ratio >10 is selected to reach high stack power density at 11,300-m cruise altitude. The propulsion system is configured to accommodate air handling within the core duct, an inclined heat exchanger in the outer duct to limit the nacelle size, and variable area nozzles to independently control mass flows through the core and bypass ducts. The airframe is modified for maximum lift coefficient and longer balanced field length for dramatically reduced thrust during take-off, and the fuselage is stretched by 20% to store liquid hydrogen (LH 2 ). Modularization of power systems promotes safety in one engine inoperative scenarios and allows reaching specific power metrics for stack, balance-of-plant and fuel cell system (FCS), necessary for acceptable take-off weight. In conclusion, cost parity requires increase in FCS lifetime, LH 2 cost reduction, and improved FCS specific power.

Catalyst durability↗

DOE OSTI2023

Performance Characteristics of a Rotating Detonation Combustor Exiting Into a Pressurized Plenum to Simulate Gas Turbine Inlet

Abstract The present study aims to experimentally characterize the performance of a rotating detonation combustion (RDC) system integrated with a pressurized downstream plenum to simulate the high-pressure inlet conditions of power-generating gas turbines. A thorough understanding of the operational behavior including wave mode behavior, static pressure profile along the combustor length, and dynamic features of pressure fluctuations is crucial for successful integration of RDC with the turbine. In this study, two RDC configurations are investigated, RDC with a constant area annulus and RDC with a converging nozzle. In both cases, the RDC flow exited into a plenum chamber kept at pressures varying from 155 kPa to 330 kPa. RDC was operated on methane and oxygen-enriched air to represent reactants used in land-based power generation. Experiments were conducted for the two RDCs configurations operated at three reactant mass flow rates (0.23, 0.32, and 0.46 kg/s). The RDC performance is characterized by time-averaged static pressure measurements, and wave velocity determined by ionization probes. In addition, dynamic pressure measurements were recorded both inside and near the exit of RDC channel to investigate wave interactions between RDC and downstream plenum. Results show that the RDC with the converging nozzle achieved superior performance while minimizing detrimental interactions with the reflected shock and/or acoustic waves from the downstream plenum.

Engineering↗

DOE OSTI2022

Validation of Calibrated k–ε Model Parameters for Jet-in-Crossflow

Previous efforts determined a set of calibrated, optimal model parameter values for Reynolds-averaged Navier–Stokes (RANS) simulations of a compressible jet in crossflow (JIC) using a $k–ε$ turbulence model. These parameters were derived by comparing simulation results to particle image velocimetry (PIV) data of a complementary JIC experiment under a limited set of flow conditions. Here, a $k–ε$ model using both nominal and calibrated parameters is validated against PIV data acquired from a much wider variety of JIC cases, including a realistic flight vehicle. The results from the simulations using the calibrated model parameters showed considerable improvements over those using the nominal values, even for cases that were not used in the calibration procedure that defined the optimal parameters. This improvement is demonstrated using a number of quality metrics that test the spatial alignment of the jet core, the magnitudes of multiple flow variables, and the location and strengths of vortices in the counter-rotating vortex cores on the PIV planes. These results suggest that the calibrated parameters have applicability well outside the specific flow case used in defining them and that with the right model parameters, RANS solutions for the JIC can be improved significantly over those obtained from the nominal model.

42 ENGINEERING↗

DOE OSTI2020

Numerical study on spray collapse process of ECN spray G injector under flash boiling conditions

This work features a numerical study of the spray collapse process that occurs under flash-boiling, gasoline-direct-injection conditions. The Engine Combustion Network's Spray G injector was modeled, and iso-octane, n-hexane, and propane were used as fuels with the goal to investigate fuel property effects. The development of individual jets and jet-to-jet interaction were analyzed to reveal the physical mechanisms of spray collapse. The results agreed qualitatively well with the experimental data of propane available from the literature and the predictions revealed the model's ability to capture the near-nozzle shock structures witnessed in the experiments. Simulations showed that the flow development of flashing sprays was strongly tied with the fuel properties. Specifically, under-expanded jets were not observed with iso-octane due to the fuel's low vapor pressure. In the case of n-hexane, the jets were under-expanded, and a low-pressure core was observed inside the jets due to the flow expansion. With propane, the very strong expansion caused the flow to become transonic and generate a unique shock structure near the nozzle exit. The shock structure revealed the formation of primary shock cells within the jets and secondary shock cells induced by jet-to-jet interaction. Based on the results, the spray collapse under flash boiling conditions was mainly attributed to two effects, i.e., the decrease in pressure at the spray center induced by the low-pressure cores inside and between the jets, and the isolation effect due to the jet-to-jet interaction which contributed to maintain the pressure differential between the spray center and the ambient.

42 ENGINEERING↗

DOE OSTI2023

Comparative Thermal Performance of Downdraft and Updraft Forced Convection in a Representative 3x3 PWR Fuel Assembly

A plethora of theoretical, numerical, and experimental investigations have relied on updraft forced convection of operating fuel assemblies for light water-cooled fuel assemblies. The inertial scales of turbulence in updraft flow through PWR fuel assemblies are primarily influenced by upstream mixing patterns within the lower plenum and consequent acceleration of flow through the lower core and support plates into the bottom nozzles. In secondary heat transfer applications such as steam generation, recuperation and economization, downdraft flow is utilized to retrieve maximal sensible heat from the primary coolant. Sub-channel volumes aligned vertically could also benefit from force of gravity in developing turbulent flows. A large reduction in pumping power, associated cost of operation and maintenance, and improved balance of plant is suggested to be possible through downdraft forced convection in PWR-type reactors. This article explores the impact of downdraft forced convection within the well-studied 3x3 sub-channel within a range of 20 hydraulic diameters across a representative intermediate flow mixing grid. A range of inflow Reynolds number from 10,000 to 60,000 is simulated over a range of equivalent heat loads of 20% to 100% spanning 20 hydraulic diameters. The fuel rods are represented in true geometric detail, and a constant-value heat profile is assumed for the investigation. At each inflow condition, the turbulence intensity, peak velocity, local heat transfer coefficient, peak wall heat flux, and peak wall temperature are collected across the sub-channel and compared with an updraft configuration evaluated at the same conditions.

Rao, Vivek↗

DOE OSTI2022

Enhanced energy conversion efficiency promoted by cavitation in gasoline direct injection

High-pressure direct fuel injection plays the most crucial role in energy conversion and improving engine combustion efficiency and emission. The optimization of turbulent and multiphase fuel injection has focused on controlling hydrodynamic parameters such as injection pressure. While the thermodynamic influence is often considered in the flash boiling situation, we inquire into how gasoline-type fuel’s hydro- and thermodynamic properties impact the injection dynamics by fuel-temperature induced cavitation. The turbulent and cavitating flows emanating from the direct-injection nozzle is visualized by ultrafast x-ray imaging with an unprecedented spatiotemporal resolution. The ultrafast liquid-fuel dynamics are dominated by injection pressure as well as fuel temperature through cavitation, an important thermodynamic parameter but often difficult to control in engine combustion. With the most direct and quantitative measurement, we discovered that the near-nozzle fuel-jet dynamics can be perfectly scaled by a single dimensionless parameter, cavitation number, particularly sensitive to the fuel temperature, in a wide operation range. This universal scaling shows that cavitation can be harnessed to elevate the pneumatic-hydraulic to kinetic energy conversion efficiency, critical for promoting fuel atomization and engine combustion performance. This enhancement effect will have even more impact on engine combustion using alternative low-emission fuels with higher saturated vapor pressure.

30 DIRECT ENERGY CONVERSION↗

DOE OSTI2022

Ambient-temperature liquid jet targets for high-repetition-rate HED discovery science

High-power lasers can generate energetic particle beams and astrophysically relevant pressure and temperature states in the high-energy-density (HED) regime. Recently-commissioned high-repetition-rate (HRR) laser drivers are capable of producing these conditions at rates exceeding 1 Hz. However, experimental output from these systems is often limited by the difficulty of designing targets that match these repetition rates. To overcome this challenge, we have developed tungsten microfluidic nozzles, which produce a continuously replenishing jet that operates at flow speeds of approximately 10 m/s and can sustain shot frequencies up to 1 kHz. The ambient-temperature planar liquid jets produced by these nozzles can have thicknesses ranging from hundreds of nanometers to tens of micrometers. In this work, we illustrate the operational principle of the microfluidic nozzle and describe its implementation in a vacuum environment. Further, we provide evidence of successful laser-driven ion acceleration using this target and discuss the prospect of optimizing the ion acceleration performance through an in situ jet thickness scan. Future applications for the jet throughout HED science include shock compression and studies of strongly heated nonequilibrium plasmas. When fielded in concert with HRR-compatible laser, diagnostic, and active feedback technology, this target will facilitate advanced automated studies in HRR HED science, including machine learning-based optimization and high-dimensional statistical analysis.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

DOE OSTI2021

Development of dispensing hardware for safe fueling of heavy duty vehicles

The development of safe dispensing equipment for the fueling of heavy duty (HD) vehicles is critical to the expansion of this newly and quickly expanding market. This paper discusses the development of a HD dispenser and nozzles assembly (nozzle, hose, breakaway) for these new, larger vehicles where flow rates are more than double compared to light duty (LD) vehicles. This equipment must operate at nominal pressures of 700 bar, -40o C gas temperature, and average flow rate of 5-10 kg/min at a high throughput commercial hydrogen fueling station without leaking hydrogen. The project surveyed HD vehicle manufacturers, station developers, and component suppliers to determine the basic specifications of the dispensing equipment and nozzle assembly. The team also examined existing codes and standards to determine necessary changes to accommodate HD components. From this information, the team developed a set of specifications which will be used to design the dispensing equipment. In order to meet these goals, the team performed computational fluid dynamic, pressure modelling, and temperature analysis in order to determine the necessary parameters to meet existing safety standards modified for HD fueling. The team also considered user, operational, and maintenance requirements, such as freeze lock which has been an issue which prevents the removal of the nozzle from LD vehicles. The team also performed a failure mode and effects analysis (FMEA) to identify the possible failures in the design. The dispenser and nozzle assembly will be tested separately, and then installed on an innovative, HD fueling station which will use a HD vehicle simulator to test the entire system.

08 HYDROGEN↗

DOE OSTI2023

Analytical Study and Experimental Verification of Shear-Thinning Ink Flow in Direct Ink Writing Process

Abstract Direct ink writing (DIW) process is a facile additive manufacturing technology to fabricate three-dimensional (3D) objects with various materials. Its versatility has attracted considerable interest in academia and industry in recent years. As such, upsurging endeavors are invested in advancing the ink flow behaviors in order to optimize the process resolution and the printing quality. However, so far, the physical phenomena during the DIW process are not revealed in detail, leaving a research gap between the physical experiments and its underlying theories. Here, we present a comprehensive analytical study of non-Newtonian ink flow behavior during the DIW process. Different syringe-nozzle geometries are modeled for the comparative case studies. By using the computational fluid dynamics (CFD) simulation method, we reveal the shear-thinning property during the ink extrusion process. Besides, we study the viscosity, shear stress, and velocity fields, and analyze the advantages and drawbacks of each syringe-nozzle model. On the basis of these investigations and analyses, we propose an improved syringe-nozzle geometry for stable extrusion and high printing quality. A set of DIW printing experiments and rheological characterizations are carried out to verify the simulation studies. The results developed in this work offer an in-depth understanding of the ink flow behavior in the DIW process, providing valuable guidelines for optimizing the physical DIW configuration toward high-resolution printing and, consequently, improving the performance of DIW-printed objects.

Engineering↗

DOE OSTI2021

Out of the Lab: 3D Printing on Non-Ideal Surfaces

In this work, coaxial direct ink writing is utilized to print sensitive or encapsulated materials onto heterogeneous and rough substrates. By enclosing the core fluid within a rigid ceramic shell, continuity is maintained even when printing on substrates traditionally considered challenging. This work presents the development of a coaxial ceramic direct ink writing system and investigates co-flow dynamics through microfluidic principles. A specially designed coaxial nozzle enables the co-extrusion of an alumina shell, with indium-tin-oxide inks serving as the core material. This approach allows the fabrication of core-shell ceramic structures suitable for future high-temperature applications on rough surfaces. The colloidal inks are tailored to achieve the necessary rheological properties and sintering performance. Additionally, flow simulations, guided by microfluidic co-flow principles, are employed to define the processing parameters for coaxial printing, ensuring precise control over the core-shell architectures. Physical modeling is further applied to study core deformation and eccentricity. These simulations are experimentally validated, supporting the successful deposition of coaxial ceramic features on heterogeneous, high-temperature ceramic substrates.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2024

Breakup dynamics in a pressure-swirl injector for urea-water solution applications: A computational study

The co-optimization of in-cylinder combustion and after-treatment technology has become a major aspect in engine design and development, with the goal of meeting the increasingly restrictive emission regulations in the transportation industry. Selective Catalytic Reduction is a robust technology to control the emission of NO x , and the injection of urea in water solution is the exhaust tailpipe is a key aspect of its operation. The proposed work uses high-fidelity Computational Fluid Dynamics to characterize the atomization dynamics of the liquid jet in relevant cross-flow conditions. The study focuses on a commercial low-pressure (9 bar) pressure-swirl injector which is characterized in its internal geometry through high-resolution X-ray micro-computational tomography. The internal two-phase flow has been modeled according to the volume-of-fluid approach in a large eddy simulation framework and validated against near-nozzle X-ray radiography measurement. Moreover, characterizing the breakup dynamics for the swirling hollow cone formation, and assessing the influence of the cross-flow in the breakup dynamics was completed. The results have been reported proposing Re-Oh maps and probability density functions of the spray kinematics. Higher cross-flow momentum generates an increase in the jet intact length and a reduction of the liquid droplet diameters. The axial momentum of the jet is affected by the cross-flow already in the near-nozzle region, determining a relevant deviation of the spray velocities. In conclusion, this work aims to inform the initialization of Eulerian-Lagrangian spray models through the assignment of droplet kinematics and static one-way coupling between volume-of-fluid results and Lagrangian spray parcels, to be used for system-size domain simulations.

33 ADVANCED PROPULSION SYSTEMS↗