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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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At least 91 records · Page 5

Probing complex geophysical geometries with chattering dust

Abstract The modern energy economy and environmental infrastructure rely on the flow of fluids through fractures in rock. Yet this flow cannot be imaged directly because rocks are opaque to most probes. Here we apply chattering dust, or chemically reactive grains of sucrose containing pockets of pressurized carbon dioxide, to study rock fractures. As a dust grain dissolves, the pockets burst and emit acoustic signals that are detected by distributed sets of external ultrasonic sensors that track the dust movement through fracture systems. The dust particles travel through locally varying fracture apertures with varying speeds and provide information about internal fracture geometry, flow paths and bottlenecks. Chattering dust particles have an advantage over chemical sensors because they do not need to be collected, and over passive tracers because the chattering dust delineates the transport path. The current laboratory work has potential to scale up to near-borehole applications in the field.

58 GEOSCIENCES↗

Engine and fuel cell system including first and second turbochargers

An engine system includes an internal combustion engine, a fuel cell system, a first turbocharger and a second turbocharger. The internal combustion engine has an intake passage, and a first exhaust passage fluidly connected to the first set of combustion chambers. The first turbocharger has a first compressor and a first turbine. The second turbocharger has a second compressor and a second turbine, the second compressor connected in series with the first compressor, and the second turbine being in fluid communication with the second exhaust passage. The first and second turbines are connected in parallel such that the first turbine only receives exhaust flow from the fuel cell system, and the second turbine only receives exhaust flow from the internal combustion engine.

Lusardi, Christopher↗

Enabling high rate capability, low internal resistance, and excellent cyclability for vanadium redox flow batteries utilizing ultrafast laser-structured graphite felt

The electrochemical performance of vanadium redox flow batteries (VRFBs) was enhanced via laser-patterned graphite felt (GF) electrodes. The laser-structured GF electrodes engineered via preparing a series of well-ordered microscopic channel structures with an average width of 200 μm, creating a three-dimensional carbon framework. The ultrafast laser patterning increased the porosity by 10%, as compared to pristine electrode. The analysis of the overpotential distribution using electrochemical impedance spectroscopy revealed that the electrode polarization involving charge transfer and diffusion resistance is strongly alleviated with the aid of carbon micro-perforation. The advanced design of laser-structured GF electrode also exhibits high rate capability, low internal resistance, and excellent cyclability. The improved performance was attributed to the synergistic effect involving (i) high electrochemically active surface area for rapid electrochemical reactions (i.e., V(II)/V(III) and V(IV)/V(V) redox couples) and (ii) excellent transport properties for facile electron/ion/species transport. The micro-scale channels created with the laser-ablation technique act as capillary structures and enabled homogeneous and rapid wetting of GF electrodes as formulated with the classical Washburn equation. The VRFB equipped with the laser-structured GF electrodes delivered a high discharge capacity with exceptional capacity retention upon extended cycling (>84.9%). In conclusion, accordingly, the design of laser-structured electrode paves the pathway towards finely tuning the electrode internal microstructure for improved cyclability, durability, and capacity retention in various electrochemical energy storage/conversion devices (e.g. all-vanadium redox flow batteries).

25 ENERGY STORAGE↗

Computational Fluid Dynamics Using the Adaptive Wavelet-Collocation Method

Advancements to the adaptive wavelet-collocation method over the last decade have opened up a number of new possible areas for active research. Volume penalization techniques allow complex immersed boundary conditions to be used with high efficiency for both internal and external flows. Anisotropic methods make it possible to use body-fitted meshes while still taking advantage of the dynamic adaptability properties wavelet-based methods provide. The parallelization of the approach has made it possible to perform large high-resolution simulations of detonation initiation and fluid instabilities to uncover new physical insights that would otherwise be difficult to discover. Other developments include space-time adaptive methods and nonreflecting boundary conditions. This article summarizes the work performed using the adaptive wavelet-collocation method developed by Vasilyev and coworkers over the past decade.

42 ENGINEERING↗

Bulk Spray and Individual Plume Characterization of LPG and Iso-Octane Sprays at Engine-Like Conditions

This study presents experimental and numerical examination of directly injected (DI) propane and iso-octane, surrogates for liquified petroleum gas (LPG) and gasoline, respectively, at various engine like conditions with the overall objective to establish the baseline with regards to fuel delivery required for future high efficiency DI-LPG fueled heavy-duty engines. Sprays for both iso-octane and propane were characterized and the results from the optical diagnostic techniques including high-speed Schlieren and planar Mie scattering imaging were applied to differentiate the liquid-phase regions and the bulk spray phenomenon from single plume behaviors. The experimental results, coupled with high-fidelity internal nozzle-flow simulations were then used to define best practices in CFD Lagrangian spray models. Optical imaging revealed that unlike iso-octane, propane’s spray propagation was fed by its flash boiling, spray collapse, and high degree of vaporization, resulting in a direct proportionality of propane’s penetration length to temperature. These unique features of propane and its variation from iso-octane’s spray pattern, contributed to its classification as an unconventional spray. Appropriate corrections to the injection and breakup models were developed to reproduce the under-expanded jet dynamics and to mimic the flash boiling-driven spray development observed with propane sprays. The simulation results were found to be sensitive to cone and inclusion angles of the blob injector. The current work represents a first assessment of the capability of the commonly available models for engine-spray simulations and highlights the fact that, despite the reasonable agreement obtained in the fuel vapor morphology, the representation of the liquid phase lacks accuracy and requires further model development.

02 PETROLEUM↗

Generation of E × B flow shear by finite orbit width effects from heat sources in tokamaks

Here we present a possible mechanism for the generation of strong E × B flow shear relevant to internal transport barrier formation in tokamak plasmas. From gyrokinetic calculations, we show that strong E × B flow shear can be generated by finite orbit width (FOW) effects associated with a non-uniform heat source and is sufficient to lead to transport barrier formation in the core region with a moderate power level. Two FOW effects inducing neoclassical polarization are shown to be responsible for this: (1) the radial drift of particle orbit center due to the variation of the heat source within orbit width and (2) the non-uniformly evolved orbit width by the non-uniform heating.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Low-Reynolds-number oscillating boundary layers on adiabatic slopes

We investigate the instabilities and transition mechanisms of Boussinesq stratified boundary layers on sloping boundaries when subjected to oscillatory body forcing parallel to the slope. We examine idealized forms of boundary layers on hydraulically smooth abyssal slopes in tranquil mid- to low-latitude regions, where low-wavenumber internal tides gently heave isopycnals up and down adiabatic slopes in the absence of mean flows, high-wavenumber internal tides, shelf breaks, resonant tide–bathymetry interactions (critical slopes) and other phenomena associated with turbulence ‘hot spots’. In non-rotating low-Reynolds-number flow, increased stratification on the downslope phase has a relaminarizing effect, while on the upslope phase we find transition-to-turbulence pathways arise from shear production triggered by gravitational instabilities. When rotation is significant (low slope Burger numbers) we find that boundary layer turbulence is sustained throughout the oscillation period, resembling stratified Stokes–Ekman layer turbulence. Simulation results suggest that oscillating boundary layers on smooth slopes at low Reynolds number ($Re\leqslant 840$), unity Prandtl number and slope Burger numbers greater than unity do not cause significant irreversible turbulent buoyancy flux (mixing), and that flat-bottom dissipation rate models derived from the tide amplitude are accurate within an order of magnitude.

42 ENGINEERING↗

Development of a Time-Height Profile Assimilation Technique for Large-Eddy Simulation

Mesoscale-to-microscale coupling (MMC) aims to address the limited scope of traditional large-eddy simulations by driving the microscale flow with information concerning large-scale weather patterns provided by mesoscale models. We present a new offline MMC technique for horizontally homogeneous microscale flow conditions, in which internal forcing terms are computed based on mesoscale time–height profiles of mean-flow quantities. The advantage of such an approach is that it can be used to drive a microscale simulation with either mesoscale or observational data, and that it does not rely on specific terms in the mesoscale budget equations, which are typically not part of the default output of a mesoscale solver. The performance of the proposed profile assimilation technique is assessed based on the simulation of a typical diurnal cycle over the Scaled Wind Farm Technology site in west Texas. Results indicate that simple data assimilation techniques lead to unphysically high levels of shear and turbulence caused by the algorithm’s inability to cope with inaccuracies in the mesoscale time–height profiles. Modifying the algorithm to account for vertical coherence in the mesoscale source terms gives the microscale solver a greater ability to correct the provided mesoscale time–height profiles, leading to improved predictions of shear and turbulence statistics. The resulting turbulence statistics are in good agreement with meteorological tower observations and simulation results obtained with state-of-the-art coupling techniques using mesoscale budget components.

data assimilation↗

Revolutionizing Turbine Cooling with Micro-Architectures Enabled by Direct Metal Laser Sintering

The objective of this research effort was to explore innovative cooling architectures enabled by additive manufacturing techniques for improved turbine cooling performance. The ability to create complex internal geometries was leveraged to better distribute coolant as well as to integrate inherently unstable flow devices to enhance internal and external heat transfer. This was accomplished with a multi-faceted approach including analytical, experimental, and computational components. This final report documents progress during the total 4.25 year effort that was extended (at no additional cost) from the original 3-year cooperative agreement. Prior to starting the project, significant effort was invested in investigating innovative cooling designs from the open literature. When the project started, we quickly down-selected to 4 configurations: impingement jet fluidic oscillators (for internal leading edge cooling), reverse film cooling (for pressure surface), sweeping film cooling jets (for suction surface), and trailing edge slot cooling with microchannels. During the 2nd year, the reverse film cooling design was shown to be sub-optimal and work on that topic was halted. The three remaining technologies were integrated into a large scale nozzle guide vane and installed into a low-speed linear cascade facility for further interrogation. Initial results showed the sweeping film cooling jets (on the suction surface) to be the most promising technology compared to a baseline diffusion shaped film hole (777 design). The benefit was particularly evident at high blowing ratios (>1.5) when the 777 coolant film separated from the downstream surface. Benefits were also evident at elevated freestream turbulence levels. The leading edge cooling with unsteady jets was less effective in terms of peak or average cooling – however it was superior to round hole impingement cooling in terms of spatial uniformity. Finally, the trailing edge cooling design with micro-channels was scrapped in favor of a pinned arrangement with centerbody. During the 3rd year, the same three technologies were integrated into a transonic linear cascade for an assessment of compressibility effects. Again, the sweeping film cooling jets proved superior at high blowing ratios while the unsteady leading edge impingement and trailing edge pin-fins with centerbody designs yielded mixed results. Finally, during the 4th and final year, these 3 technologies were integrated into a direct metal laser sintered (DMLS) nozzle guide vane for testing in a high temperature, transonic annular vane cascade. The facility matches the flow temperature, Mach number, and coolant pressure ratios of an actual gas turbine. Before doing this, an additional series of tests were completed to validate a redesigned trailing edge cooling architecture. This final design included a centerbody with triangular pins between the centerbody and the vane external skin. The majority of these triangular pins are fabricated with a 30% gap to the centerbody – reducing their pressure drop considerably while still providing excellent heat transfer augmentation. This additional test campaign required an additional 3-month extension request to complete testing in the high temperature NGV test facility (Turbine Reacting Flow Rig – TuRFR). Testing of the DMLS vane in TuRFR pitted the 3 innovative cooling technologies against more traditional technologies (shaped 777 film hole, round impingement jet, and full pin arrangement in the trailing edge. The sweeping film cooling jets (on the suction surface) showed approximately 15% improvement in overall effectiveness compared to the 777 film hole while the trailing edge showed up to 20% improvement. The leading edge impingement was disappointing with a substantially lower effectiveness than traditional direct impingement. In summary, the study was successful in demonstrating that DMLS-enabled cooling technologies can yield significant gains in cooling performance.

03 NATURAL GAS↗

Improved representation of laminar and turbulent sheet flow in subglacial drainage models

Subglacial hydrology models struggle to reproduce seasonal drainage patterns that are consistent with observed subglacial water pressures and surface velocities. We modify the standard sheet-flow parameterization within a coupled sheet–channel subglacial drainage model to smoothly transition between laminar and turbulent flow based on the locally computed Reynolds number in a physically consistent way (the ‘transition’ model). We compare the transition model to standard laminar and turbulent models to assess the role of the sheet-flow parameterization in reconciling observed and modelled water pressures under idealized and realistic forcing. Relative to the turbulent model, the laminar and transition models improve seasonal simulations by increasing winter water pressure and producing a more prominent late-summer water pressure minimum. In contrast to the laminar model, the transition model remains consistent with its own internal assumptions across all flow regimes. Based on the internal consistency of the transition model and its improved performance relative to the standard turbulent model, we recommend its use for transient simulations of subglacial drainage.

54 ENVIRONMENTAL SCIENCES↗

CFD simulations of Molten Salt Fast Reactor core cavity flows

Computational Fluid Dynamics (CFD) has become increasingly important in the research and development of advanced nuclear reactors. Here, in the current study, extensive CFD simulations were conducted for the coolant flow in Molten Salt Fast Reactor (MSFR) core models using the state-of-the-art spectral element flow solver Nek5000 and multiscale coarse-mesh thermal-hydraulic software Pronghorn. The underlying motivation is to seek an in-depth understanding of how the internal velocity distribution can be influenced by the MSFR core cavity shape, the Reynolds number, turbulence modeling options and the inlet boundary conditions. The CFD techniques involved in this investigation range from coarse-mesh CFD, RANS modeling, to the high-fidelity LES calculations. Specifically, a series of RANS simulations were performed for the 2-D axisymmetric core model and 3-D wedge domains to study the flow distribution inside the MSFR core. It is observed that a proper representation of the MSFR inlet channel duct is important for the prediction of internal flow distribution. It is also showcased here how researchers can leverage the Nek5000 CFD results to calibrate more efficient coarse-mesh CFD tools, like Pronghorn, for the actual MSFR design needs. Moreover, this paper highlights a 3-D LES model for an entire MSFR core using the spectral element method and demonstrates the feasibility of this modeling approach. The readiness and potential limitations of the RANS approach are examined with respect to the high-fidelity LES simulations. The present investigation lays a solid foundation as we are leveraging the high-fidelity CFD capabilities to inform MSFR design efforts.

97 MATHEMATICS AND COMPUTING↗

Coregistered positron emission particle tracking (PEPT) and X-ray computed tomography (CT) for engineering flow measurements

Increasingly, fully 3D experimental measurements of flow in complex engineering geometries are required to validate computational fluid dynamics models that support and inform reactor design and licensing. One barrier to such measurements is the complexity of typical reactor components and subsequent lack of optical access in these systems. To overcome this, the deployment of coregistered positron emission particle tracking (PEPT) and X-ray computed tomography (CT) is explored for flow measurement in reactor thermal hydraulic components and model (scaled) systems. Through this methodology, fully 3D flow information (via PEPT) and detailed internal geometry (via CT) are captured in opaque systems such as pipes, rod bundles, packed beds, etc. The reconstructed flow field and geometry can then be overlain to reveal detailed flow features around internal structures within a given test section. This is enabled through the use of a combined preclinical PET/CT scanner with overlapping PET and CT fields of view. Such measurements are useful for characterizing flow inside such intricate nuclear thermal hydraulic components as core geometries and heat exchangers, among others, and providing valuable 3D validation data for CFD models. In this work, basic tests of this 3D flow/geometry mapping are presented, and the implications of such measurements are discussed. Further, preliminary measurements are made with both point sources and flow in a simple pipe flow geometry to evaluate the capabilities of this technique. PEPT and CT features are coregistered with up to 0.1 mm precision, and pipe flow mean velocity and Reynolds stresses are reconstructed with similar accuracy to previous PEPT demonstrations. The utility of PEPT/CT is shown herein, and suggestions for future measurements are made.

3D flow measurement↗

Measurements of the Flow in the Vicinity of an Additively Manufactured Turbine Leading-Edge Using X-Ray Particle Tracking Velocimetry

X-ray particle tracking velocimetry (PTV) is performed, for the first time, to measure the velocity field inside a leading-edge of a turbine blade made by laser-additive-manufacturing (LAM) process. The traditional showerhead holes were replaced by a porous matrix in the leading-edge. The flow through such a leading-edge piece cannot be faithfully recreated by traditional prototype testing methods due to the surface roughness and imperfections caused by LAM process. Hence, direct measurement is the only option. However, it is difficult to measure flow inside such pieces with traditional velocimetry measurements due to the existence of metallic walls. Moreover, small internal size and high flow speeds call for a measurement technique with high spatial and temporal resolutions. To address these issues, we performed time-resolved X-ray PTV using the Advanced Photon Source (APS) synchrotron facility at the Argonne National Laboratory (ANL). A hydraulic system was constructed to run water, mixed with seeding particles, through the leading-edge piece. A high-speed camera captured the images of the seeding particles, which were later processed to create particle tracks. The time-averaged velocity field showed distinct pairs of vortices located in front of the porous outlet inside the leading-edge piece. The inlet channel showed reversed flow due to partial obstruction by the porous inlet of the test piece. Such knowledge of the flow field inside a leading-edge of a turbine blade will help us to design better cooling paths leading to higher cooling efficiency and increased life-span of a turbine blade.

42 ENGINEERING↗

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↗

The Effect of Flow on CO2 Corrosion of Self-Healing Metallic Coatings

Internal corrosion is an issue that affects natural gas pipelines, a significant part of the United States’ energy infrastructure. Over time, this corrosion has worn away longstanding pipelines due to the original construction materials used for the lines and impurities in the gas and liquid streams flowing through them. The main impurities in natural gas are H2O, CO2, H2S, and O2. One of the leading causes of corrosion is the CO2 dissolved in water, giving rise to carbonic acid formation, which can further dissolve the steel pipe. The National Energy Technology Laboratory (NETL) has been studying different solutions to this problem. One potential answer is a self-healing sacrificial metallic coating applied by a novel cold spray technique. This study explored the impact of flow on corrosion with this coating and carbon steel when exposed to a saturated CO2 environment by simulating the pipeline flow profile in a small-scale lab setting. The samples were evaluated using multiple electrochemical techniques that found corrosion rates and were backed up with surface analysis to conclude the behavior of the corrosion mechanisms. The cold spray coating exhibited steel corrosion protection under flow conditions. This study has significantly advanced our understanding of CO2 corrosion, particularly in the context of natural gas pipelines and coating design.

carbon steel↗

Heat Transfer Coefficients of Additively Manufactured Tubes with Internal Pin Fins for Supercritical Carbon Dioxide Cycle Recuperators

This paper describes the measurement of convective heat transfer coefficients and friction factors for sCO 2 flowing in additively manufactured tubes with internal pin fins at the US DOE’s National Energy Technology Laboratory in Morgantown, WV. The measurement procedures were validated by conducting benchmark tests with smooth stainless-steel tube and comparing the results with published correlations for Nusselt number (Nu) and friction factor. Over Reynolds numbers (ReD) ranging from 5 × 10 4 to 2.5 × 10 5 , measured Nu was within 5% of the Dittus-Boelter correlation and measured friction factors were within 5% of the McAdams correlation for smooth tube flow. The candidate pin fin patterned pipes were additively manufactured (AM) at the Oak Ridge National Laboratory. The pins were circular or elliptical in cross-section and were printed at a 30⁰ angle relative to the inner wall (to meet AM constraints). The pin arrangement was helical to promote enhanced heat transfer due to swirl flow. Pin length to diameter aspect ratio was 1.33, 2, and 8, while the pin diameter to tube diameter ratio was 0.188, 0.125, and 0.063. Tests were performed for ReD varying from 6.9 × 10 4 to 2.2 × 10 5 and at conditions equivalent to the low pressure (LP) outlet (8.69 MPa, 361 K) and the high pressure (HP) inlet (20.7 MPa, 350 K) of the low temperature recuperator (LTR) in an indirect sCO 2 cycle. The Wilson plot technique was utilized to measure the bulk heat transfer coefficients. For the best performing design (tube A, pin length to tube diameter ratio: 1.33, pin diameter to tube diameter ratio: 0.19), the local heat transfer coefficient increased by 136% relative to the Dittus-Boelter correlation at the LTR low pressure outlet and 194% at the LTR high pressure inlet. These correspond to a 282% and a 271% increase in the product of the heat transfer coefficient and surface area (adjusted for fin efficiency) product, respectively. Large pressure drops across the test articles were observed. For Tube Design A, the average friction factor, across the range of ReD considered, was significantly larger than the McAdams correlation at both the LTR LP outlet and the LTR HP inlet. A thermal performance factor was utilized to express the ratio of material required to build a finned heat exchanger relative to a finless heat exchanger with the same heat duty and pumping power. Tube Design A was estimated to decrease the required heat exchanger material by 13%.

Searle, Matthew↗

Synchrotron X-ray based particle image velocimetry to measure multiphase streamflow and densitometry

Synchrotron-based radiation techniques are increasingly used in the field of flow condition measurements. As a complicated multiphase flow, cavitation has been investigated in a wide variety of industrial fields, to prevent damages on spillways at large dams or intensify the bacteria eradication rate during water treatments. To control the detrimental effects of cavitating flows, the dynamics of and mechanisms affecting cavitation development shall be visualized and identified in real-time. Due to the large reflection and scattering effects of multiphase flow, standard visible-light imaging technologies cannot penetrate vapor bubbles and provide extremely limited information. In this study, the synchrotron source emitted high-flux X-ray pulses are used to capture flow motion and visualize internal structures with sufficiently high spatial and temporal resolutions. The image processing procedures on raw x-ray images are developed using 2D Fourier transform (FT) and wavelet transform (WT) to implement the contrast enhancement and de-noising. Through the edge detection algorithm, tracking either seeded particles or phase interfaces inside the opaque multiphase flow can be achieved to perform the particle image velocimetry. Further, with decomposing particle-only and particle-eliminated subplots from the X-ray phase-contrast image, the time-resolved velocity and void fraction fields are obtained simultaneously, paving a way for further flow condition analysis such as densitometry.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

Internally cooled membrane-based absorber for dehumidification and water heating: Validated model and simulation study

This report presents a comprehensive model for advanced membrane-based absorber components accounting for three separate fluid streams, one of them providing internal cooling, with complex flow patterns. The model was implemented with various liquid desiccants and their properties (including LiCl, CaCl 2 , and [emim][OMS] ionic liquid [IL]). The model has been validated using data from two laboratory prototype absorbers, one with CaCl 2 as the working fluid and one with an IL as the working fluid. Entropy analysis was further carried out to verify the model and understand effect of internal cooling on the entropy variation of three fluid streams. The developed model and codes are expected to enable detailed configuration optimization and provide in-depth understanding of three-fluid heat and mass exchanger (HMX) performance. The paper also describes parametric studies of the HMX components in utilizing the latent heat removed in space cooling to heat water and numerically explores the unique benefit of its application in a semi-open absorption heat pump water heater. The results show that a single three-fluid HMX has the potential to achieve simultaneous dehumidification and water heating efficiently at cost effectiveness, particularly in hot and humid climates.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗