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DOE OSTI2015

Predictive Engineering Tools for Injection-Molded Long-Carbon-Fiber Thermoplastic Composites - Second FY 2015 Quarterly Report

During the second quarter of FY 2015, the following technical progress has been made toward project milestones: 1) Autodesk reviewed 3D fiber orientation distribution (FOD) comparisons and provided support on improving accuracy. 2) Autodesk reviewed fiber length distribution (FLD) data comparisons and provided suggestions, assisted PNNL in FOD and FLD parameter settings optimization, and advised PNNL on appropriate through thickness thermal conductivity for improved frozen layer effect on FOD predictions. Autodesk also participated in project review meetings including preparations and discussions towards passing the go/no-go decision point. 3) Autodesk implemented an improved FOD inlet profile specification method through the part thickness for 3D meshes and provided an updated ASMI research version to PNNL. 4) The University of Illinois (Prof. C.L. Tucker) provided Autodesk with ideas to improve fiber orientation modeling 5) Purdue University re-measured fiber orientation for the fast-fill 50wt% LCF/PA66 edge-gated plaque, and delivered the fiber orientation data for this plaque at the selected locations (named A, B, and C, Figure 1) to PNNL. Purdue also re-measured fiber orientation for locations A on the fast-fill 30wt% LCF/PP and 50wt% LCF/PA66 center-gated plaques, which exhibited anomalous fiber orientation behavior. 6) Purdue University conducted fiber length measurements and delivered the length data to PNNL for the purge materials (slow-fill 30wt% LCF/PP and 30wt% LCF/PA66 purge materials) and PlastiComp plaques selected on the go/no-go list for fiber length model validation (i.e., slow-fill edge-gated 30wt% LCF/PP and 30wt% LCF/PA66 plaques, Locations A, B, and C). 7) PNNL developed a method to recover intact carbon fibers from LCF/PA66 materials. Isolated fibers were shipped to Purdue for length distribution analysis. 8) PNNL completed ASMI mid-plane analyses for all the PlastiComp plaques defined on the go/no-go list for fiber orientation (FO) model validation and compared the predicted fiber orientations with the measured data provided by Purdue at Locations A, B, and C on these plaques. The 15% accuracy criterion based on evaluation of tensile and bending stiffness was used to assess the accuracy in fiber orientation predictions. 9) PNNL completed ASMI mid-plane analyses for all the PlastiComp plaques defined on the go/no-go list for fiber length distribution (FLD) model validation and compared the predicted length distributions with the measured data provided by Purdue at Locations A, B, and C on these plaques. The 15% accuracy criterion based on evaluation of tensile and bending stiffness was used to assess the accuracy in fiber orientation predictions. 10) PNNL tested the new ASMI version received from Autodesk in March 2015, examined and discussed 3D fiber orientation predictions for PlastiComp plaques. 11) PlastiComp, Inc. (PlastiComp), Toyota Research Institute North America (Toyota) and Magna Exteriors and Interiors Corporation (Magna) participated in discussions with team members on the go/no-go plan. Toyota continued the discussion with Magna on tool modification for molding the complex part in order to achieve the target fiber length in the part.

42 ENGINEERING↗
DOE OSTI2015

Experimental Design and Comparative Testing of a Hybrid-Cooled Computer Cluster [Thesis}

With water cooling becoming an affordable option both at home and at scale, it is important to consider the possible benefits over air cooling. There are several methods of liquid cooling, notables include: immersion, cold water cooling, and warm water cooling. The total cost of ownership is difficult to determine with these options as each has a different impact on the data center. Considering retrofit, over a new data center, introduces unforeseen variables that make cost analysis a challenge. Besides the added costs of additional infrastructure, and the cost to remove old, the upfront costs could be daunting. Therefore a cost analysis would be a study of its won. This study however hopes to reveal the resulting tradeoffs in temperature, performance, and power usage presented in the case between classical airflow based heat sink mechanisms to water provided directly at the heatsink. Having control over a discrete chiller will provide answers to the CPU temperatures, power usage, and performance at various inlet water temperatures. To water or to air?

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2015

Low-Energy Solvents For Carbon Dioxide Capture Enabled By A Combination Of Enzymes And Vacuum Regeneration

An integrated bench-scale system combining the attributes of the bio-renewable enzyme carbonic anhydrase (CA) with low-enthalpy CO 2 absorption solvents and vacuum regeneration was designed, built and operated for 500 hours using simulated flue gas. The objective was to develop a CO 2 capture process with improved efficiency and sustainability when compared to NETL Case 10 monoethanolamine (MEA) scrubbing technology. The use of CA accelerates inter-conversion between dissolved CO 2 and bicarbonate ion to enhance CO 2 absorption, and the use of low enthalpy CO 2 absorption solvents makes it possible to regenerate the solvent at lower temperatures relative to the reference MEA-based solvent. The vacuum regeneration-based integrated bench-scale system operated successfully for an accumulated 500 hours using aqueous 23.5 wt% K 2 CO 3 -based solvent containing 2.5 g/L enzyme to deliver an average 84% CO 2 capture when operated with a 20% enzyme replenishment rate per ~7 hour steady-state run period. The total inlet gas flow was 30 standard liters per minute with 15% CO 2 and 85% N 2 . The absorber temperature was 40°C and the stripper operated under 35 kPa pressure with an approximate 77°C stripper bottom temperature. Tests with a 30°C absorber temperature delivered >90% capture. On- and off-line operational measurements provided a full process data set, with recirculating enzyme, that allowed for enzyme replenishment and absorption/desorption kinetic parameter calculations. Dissolved enzyme replenishment and conventional process controls were demonstrated as straightforward approaches to maintain system performance. Preliminary evaluation of a novel flow-through ultrasonically enhanced regeneration system was also conducted, yet resulted in CO2 release within the range of temperature-dependent release, and further work would be needed to validate the benefits of ultrasonic enhanced stripping. A full technology assessment was completed in which four techno-economic cases for enzyme-enhanced aqueous K 2 CO 3 solvent with vacuum stripping were considered and a corresponding set of sensitivity studies were developed. The cases were evaluated using bench-scale and laboratory-based observations, AspenPlus® process simulation and modeling, AspenTech’s CCE® Parametric Software, current vendor quotations, and project partners’ know-how of unit operations. Overall, the DOE target of 90% CO 2 capture could be met using the benign enzyme-enhanced aqueous K 2 CO 3 -based alternative to NETL Case 10. The model-predicted plant COE performance, scaled to 550 MWe net output, was 9% higher than NETL Case 10 for an enzyme-activated case with minimized technical risk and highest confidence in physical system performance utilizing commercially available equipment. A COE improvement of 2.8% versus NETL Case 10 was predicted when favorable features of improved enzyme longevity and additional power output from a very low pressure (VLP) turbine were combined, wherein corresponding high capital and operational costs limited the level of COE benefit. The environmental, health and safety (EH&S) profile of the system was found to be favorable and was compliant with the Federal EH&S legislation reviewed. Further work on a larger scale test unit is recommended to reduce the level of uncertainty inherent in extrapolating findings from a bench-scale unit to a full scale PCC plant, and to further investigate several identified opportunities for improvement. Production feasibility and suitability of carbonic anhydrases for scale-up testing was confirmed both through the current project and through parallel efforts.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2015

Brigham City Hydro Generation Project

Brigham City owns and operates its own municipal power system which currently includes several hydroelectric facilities. This project was to update the efficiency and capacity of current hydro production due to increased water flow demands that could pass through existing generation facilities. During 2006-2012, this project completed efficiency evaluation as it related to its main objective by completing a feasibility study, undergoing necessary City Council approvals and required federal environmental reviews. As a result of Phase 1 of the project, a feasibility study was conducted to determine feasibility of hydro and solar portions of the original proposal. The results indicated that the existing Hydro plant which was constructed in the 1960’s was running at approximately 77% efficiency or less. Brigham City proposes that the efficiency calculations be refined to determine the economic feasibility of improving or replacing the existing equipment with new high efficiency equipment design specifically for the site. Brigham City completed the Feasibility Assessment of this project, and determined that the Upper Hydro that supplies the main culinary water to the city was feasible to continue with. Brigham City Council provided their approval of feasibility assessment’s results. The Upper Hydro Project include removal of the existing powerhouse equipment and controls and demolition of a section of concrete encased penstock, replacement of penstock just upstream of the turbine inlet, turbine bypass, turbine shut-off and bypass valves, turbine and generator package, control equipment, assembly, start-up, commissioning, Supervisory Control And Data Acquisition (SCADA), and the replacement of a section of conductors to the step-up transformer. Brigham City increased the existing 575 KW turbine and generator with an 825 KW turbine and generator. Following the results of the feasibility assessment Brigham City pursued required environmental reviews with the DOE and the U.S. Fish and Wildlife Services (USFWS) concurring with the National Environmental Policy Act of 1969 (NEPA) It was determined that Brigham City’s Upper Hydroelectric Power Plant upgrade would have no effect to federally listed or candidate species. However Brigham City has contributed a onetime lump sum towards Bonneville cutthroat trout conservation in the Northern Bonneville Geographic Management Unit with the intention to offset any impacts from the Upper Hydro Project needed to move forward with design and construction and is sufficient for NEPA compliance. No work was done in the river or river bank. During construction, the penstock was disconnected and water was diverted through and existing system around the powerhouse and back into the water system. The penstock, which is currently a 30-inch steel pipe, would be removed and replaced with a new section of 30-inch pipe. Brigham City worked with the DOE and was awarded a new modification and the permission to proceed with Phase III of our Hydro Project in Dec. 2013; with the exception to the modification of the award for the construction phase. Brigham City developed and issued a Request for Proposal for Engineer and Design vendor. Sunrise Engineering was selected for the Design and throughout the Construction Phase of the Upper Hydroelectric Power Plant. Brigham City conducted a Kickoff Meeting with Sunrise June 28, 2013 and received a Scope of Work Brigham City along with engineering firm sent out a RFP for Turbine, Generator and Equipment for Upper Hydro. We select Turbine/Generator Equipment from Canyon Industries located in Deming, WA. DOE awarded Brigham City a new modification and the permission to proceed with Phase III Construction of our Hydro Project. Brigham City Crews removed existing turbine/generator and old equipment alone with feeder wires coming into the building basically giving Caribou Construction an empty shell to begin demolition. Brigham City contracted with Caribou Construction from Jerome, Idaho for the Upper Power Plant construction. A kickoff meeting was June 24, 2014 and demolition was immediately started on building. Because of a delivery delay of Turbine, Generator and Equipment from Canyon Brigham City had to request another extension for the final date of completion. DOE awarded modification (.007) to Brigham City with a new completion date of August 1, 2015. The Turbine has had a few adjustments to help with efficiency; but the Generator had a slight vibration when generator got hot so Canyon Industries had U S Motor’s that manufactured the generator come to check out the issue. The other Equipment seems to be running normal. Brigham City, Sunrise Engineering and Canyon Industries met to determine what the vibration in the generator was and how to solve the issue Us Motor’s found some welds that failed: they have been repaired. U S Motor’s delivered the repaired generator Feb. 17, 2015. Canyon Industries arranged for a crane to installed generator in Power Plant. U S Motor’s balanced and wired generator. Plant Operators put the generator back on line. Canyon Industries returned and gave their approval to keep Hydro online. After Hydro was put back into operations it kept going off line because of overheating issues. Canyon Industries returned and replaced sensors and adjusted them to the proper settings for normal operations. Brigham City added additional steel screens to windows to increase air flow in Power Plant Building. After construction phase of the Upper Hydro Plant some landscaping has been restored around the building additional gravel brought in and leveled out and the road that was cut through for conduits to run wires. A retaining wall was installed to protect penstock. The Upper Hydro Plant is complete and in full operations. The final reimbursement was submitted.

13 HYDRO ENERGY↗
DOE OSTI2015

Pressure distribution along the AGS vacuum chambers with new types of pump out conduits

The AGS HEBT and ring vacuum system is monitored by the discharge current of the magnet ion pumps, which is proportional to the pressure at the inlet port of these ion pumps. The discharge current is measured and suitably calibrated to indicate the ion pump pressure. In order to calculate the vacuum chamber pressure from the ion pump pressure, a detailed analysis is essential to compute their difference in different scenarios. Such analysis has been carried out numerically in the past for the system with the older type of pump out conduits, and similar analysis using FEM in ANSYS is presented in this paper with the newer type of pump out conduit.

43 PARTICLE ACCELERATORS↗
DOE OSTI2016

Effects of Hot Streak and Phantom Cooling on Heat Transfer in a Cooled Turbine Stage Including Particulate Deposition

The objective of this research effort was to develop a validated computational modeling capability for the characterization of the effects of hot streaks and particulate deposition on the heat load of modern gas turbines. This was accomplished with a multi-faceted approach including analytical, experimental, and computational components. A 1-year no cost extension request was approved for this effort, so the total duration was 4 years. The research effort succeeded in its ultimate objective by leveraging extensive experimental deposition studies complemented by computational modeling. Experiments were conducted with hot streaks, vane cooling, and combinations of hot streaks with vane cooling. These studies contributed to a significant body of corporate knowledge of deposition, in combination with particle rebound and deposition studies funded by other agencies, to provide suitable conditions for the development of a new model. The model includes the following physical phenomena: elastic deformation, plastic deformation, adhesion, and shear removal. It also incorporates material property sensitivity to temperature and tangential-normal velocity rebound cross-dependencies observed in experiments. The model is well-suited for incorporation in CFD simulations of complex gas turbine flows due to its algebraic (explicit) formulation. This report contains model predictions compared to coefficient of restitution data available in the open literature as well as deposition results from two different high temperature turbine deposition facilities. While the model comparisons with experiments are in many cases promising, several key aspects of particle deposition remain elusive. The simple phenomenological nature of the model allows for parametric dependencies to be evaluated in a straightforward manner. This effort also included the first-ever full turbine stage deposition model published in the open literature. The simulations included hot streaks and simulated vane cooling. The new deposition model was implemented into the CFD model as a wall boundary condition, with various particle sizes investigated in the simulation. Simulations utilizing a steady mixing plane formulation and an unsteady sliding mesh were conducted and the flow solution of each was validated against experimental data. Results from each of these simulations, including impact and capture distributions and efficiencies, were compared and potential reasons for differences discussed in detail. The inclusion of a large range of particle sizes allowed investigation of trends with particle size, such as increased radial migration and reduced sticking efficiency at the larger particle sizes. The unsteady simulation predicted lower sticking efficiencies on the rotor blades than the mixing plane simulation for the majority of particle sizes. This is postulated to be due to the preservation of the hot streak and cool vane wake through the vane-rotor interface (which are smeared out circumferentially in the mixing-plane simulation). The results reported here represent the successful implementation of a novel deposition model into validated vane-rotor flow solutions that include a non-uniform inlet temperature profile and simulated vane cooling.

42 ENGINEERING↗
DOE OSTI2019

Aerosol Observing System Surface Meteorology (AOSMET) Instrument Handbook

The U.S. Department of Energy (DOE)’s Atmospheric Radiation Measurement (ARM) Climate Research Facility Aerosol Observing System (AOS) surface meteorology instrument is an ancillary sensor that provides temperature, relative humidity, pressure, wind speed and direction, and precipitation data relevant to the AOS. It consists of a Vaisala WXT520 Weather Transmitter mounted on top of the AOS aerosol inlet, at a height of approximately 10 meters.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2016

Development and Testing of CTF to Support Modeling of BWR Operating Conditions

This milestone supports developing and assessing COBRA-TF (CTF) for the modeling of boiling water reactors (BWRs). This is achieved in three stages. First, a new preprocessor utility that is capable of handling BWR-specic design elements (e.g., channel boxes and large water rods) is developed. A previous milestone (L3:PHI.CTF.P12.01) led to the development of this preprocessor capability for single assembly models. This current milestone expands this utility so that it is applicable to multi-assembly BWR models that can be modeled in either serial or parallel. The second stage involves making necessary modications to CTF so that it can execute these new models. Specically, this means implementing an outer-iteration loop, specic to BWR models, that equalizes the pressure loss over all assemblies in the core (which are not connected due to the channel boxes) by adjusting inlet mass ow rate. A third stage involves assessing the standard convergence metrics that are used by CTF to determine when a simulation is steady-state. The nal stage has resulted in the implementation of new metrics in the code that give a better indication of how steady the solution is at convergence. This report summarizes these eorts and provides a demonstration of CTF's BWR-modeling capabilities. CASL-U-2016-1030-000

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2016

Complete Non-Radioactive Operability Tests for Cladding Hull Chlorination

Non-radioactive operability tests were made to test the metal chlorination reactor and condenser and their accessories using batch chlorinations of non-radioactive cladding samples and to identify optimum operating practices and components that need further modifications prior to installation of the equipment into the hot cell for tests on actual used nuclear fuel (UNF) cladding. The operability tests included (1) modifications to provide the desired heating and reactor temperature profile; and (2) three batch chlorination tests using, respectively, 100, 250, and 500 g of cladding. During the batch chlorinations, metal corrosion of the equipment was assessed, pressurization of the gas inlet was examined and the best method for maintaining solid salt product transfer through the condenser was determined. Also, additional accessing equipment for collection of residual ash and positioning of the unit within the hot cell were identified, designed, and are being fabricated.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2016

Iodine Adsorption by Ag-Aerogel under Prototypical Vessel Off-Gas Conditions

U.S. regulations will require the removal of 129 I from the off-gas streams of any used nuclear fuel (UNF) reprocessing plant prior to discharge of the off-gas to the environment. The required plant decontamination factor for iodine will vary based on fuel burnup, cooling time, and other factors but is very likely to be >1000 and could be as high as 8000. Multiple off-gas streams within a UNF reprocessing plant combine prior to environmental release, and each of these streams contains some amount of iodine. To achieve the decontamination factors (DFs) that are likely to be required by regulations, iodine removal from the vessel off-gas will be necessary. The vessel off-gas contains iodine at very dilute concentrations (ppb levels), and will also contain water vapor. Iodine species present are likely to include both elemental and organic iodides. There will also be solvent vapors and volatile radiolysis products. The United States has considered the use of silver-based sorbents for removal of iodine from UNF off-gas streams, but little is known about the behavior of those sorbents at very dilute iodine concentrations. The purpose of this study was to expose silver-functionalized silica aerogel (AgAerogel) to a prototypical vessel off-gas stream containing 40 ppb methyl iodide to obtain information about organic iodine capture by silver-sorbents at very low iodine concentrations. The design of this extended duration testing was such that information about the rate of adsorption, the penetration of the iodine species, and the overall system DF could be obtained. Results show that CH 3 I penetrates into a AgAerogel sorbent bed to a depth of 3.9 cm under prototypical vessel off-gas conditions. An iodine loading of 22 mg I/g AgAerogel was observed in the first 0.3 cm of the bed. Of the iodine delivered to the system, 48% could not be accounted for, and future efforts will investigate this concern. Direct calculation of the decontamination factor is not possible, as no iodine was observed to break through the sorbent beds. Continued studies on the adsorption of iodine from prototypical vessel off-gas streams by silver-based sorbents will attempt to resolve some of the questions raised here, both regarding mass balance and the effect of aging on iodine adsorption by AgAerogel from a dilute gas stream. Additionally, the adsorption of different iodine species, such as I 2 and C 12 H 25 I will be studied. Other variables that merit examination are the gas velocity of the test and the dependence of the observed results on the inlet iodine concentration. Finally, longer duration testing should be considered in an effort to determine the mass transfer zone associated with iodine adsorption by AgAerogel under prototypical vessel off-gas conditions. The estimation of mass transfer zone is required for any future industrial implementation.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2016

Status on the Component Models Developed in the Modelica Framework: High-Temperature Steam Electrolysis Plant & Gas Turbine Power Plant

This report has been prepared as part of an effort to design and build a modeling and simulation (M&S) framework to assess the economic viability of a nuclear-renewable hybrid energy system (N-R HES). In order to facilitate dynamic M&S of such an integrated system, research groups in multiple national laboratories have been developing various subsystems as dynamic physics-based components using the Modelica programming language. In fiscal year (FY) 2015, Idaho National Laboratory (INL) performed a dynamic analysis of two region-specific N-R HES configurations, including the gas-to-liquid (natural gas to Fischer-Tropsch synthetic fuel) and brackish water reverse osmosis desalination plants as industrial processes. In FY 2016, INL has developed two additional subsystems in the Modelica framework: a high-temperature steam electrolysis (HTSE) plant and a gas turbine power plant (GTPP). HTSE has been proposed as a high priority industrial process to be integrated with a light water reactor (LWR) in an N-R HES. This integrated energy system would be capable of dynamically apportioning thermal and electrical energy (1) to provide responsive generation to the power grid and (2) to produce alternative industrial products (i.e., hydrogen and oxygen) without generating any greenhouse gases. A dynamic performance analysis of the LWR/HTSE integration case was carried out to evaluate the technical feasibility (load-following capability) and safety of such a system operating under highly variable conditions requiring flexible output. To support the dynamic analysis, the detailed dynamic model and control design of the HTSE process, which employs solid oxide electrolysis cells, have been developed to predict the process behavior over a large range of operating conditions. As first-generation N-R HES technology will be based on LWRs, which provide thermal energy at a relatively low temperature, complementary temperature-boosting technology was suggested for integration with the HTSE process that requires higher temperature input. Simulation results involving several case studies show that the suggested control scheme could maintain the controlled variables (including the steam utilization factor, cathode stream inlet composition, and temperatures of the process streams at various locations) within desired limits under various plant operating conditions. The results also indicate that the proposed HTSE plant could provide operational flexibility to participate in energy management at the utility scale by dynamically optimizing the use of excess plant capacity within an N-R HES. A natural-gas fired GTPP has been proposed as a secondary energy supply to be included in an N-R HES. This auxiliary generator could be used to cover rapid dynamics in grid demand that cannot be met by the remainder of the N-R HES. To evaluate the operability and controllability of the proposed process during transients between load (demand) levels, the dynamic model and control design were developed. Special attention was given to the design of feedback controllers to regulate the power frequency, and exhaust gas and turbine firing temperatures. Several case studies were performed to investigate the system responses to the major disturbance (power load demand) in such a control system. The simulation results show that the performance of the proposed control strategies was satisfactory under each test when the GTPP experienced high rapid variations in the load.

08 HYDROGEN↗
DOE OSTI2017

Hybrid Molten Bed Gasifier for High Hydrogen Syngas Production

The techno-economic analyses of the hybrid molten bed gasification technology and laboratory testing of the HMB process were carried out in this project by the Gas Technology Institute and partner Nexant, Inc. under contract with the US Department of Energy’s National Energy Technology Laboratory. This report includes the results of two complete IGCC and Fischer-Tropsch TEA analyses comparing HMB gasification with the Shell slagging gasification process as a base case. Also included are the results of the laboratory simulation tests of the HMB process using Illinois #6 coal fed along with natural gas, two different syngases, and steam. Work in this 18-month project was carried out in three main Tasks. Task 2 was completed first and involved modeling, mass and energy balances, and gasification process design. The results of this work were provided to Nexant as input to the TEA IGCC and FT configurations studied in detail in Task 3. The results of Task 2 were also used to guide the design of the laboratory-scale testing of the HMB concept in the submerged combustion melting test facility in GTI’s industrial combustion laboratory. All project work was completed on time and budget. A project close-out meeting reviewing project results was conducted on April 1, 2015 at GTI in Des Plaines, IL. The hybrid molten bed gasification process techno-economic analyses found that the HMB process is both technically and economically attractive compared with the Shell entrained flow gasification process. In IGCC configuration, HMB gasification provides both efficiency and cost benefits. In Fischer-Tropsch configuration, HMB shows small benefits, primarily because even at current low natural gas prices, natural gas is more expensive than coal on an energy cost basis. HMB gasification was found in the TEA to improve the overall IGCC economics as compared to the coal only Shell gasification process. Operationally, the HMB process proved to be robust and easy to operate. The burner was stable over the full oxygen to fuel firing range (0.8 to 1.05 of fuel gas stoichiometry) and with all fuel gases (natural gas and two syngas compositions), with steam, and without steam. The lower Btu content of the syngases presented no combustion difficulties. The molten bed was stable throughout testing. The molten bed was easily established as a bed of molten glass. As the composition changed from glass cullet to cullet with slag, no instabilities were encountered. The bed temperature and product syngas temperature remained stable throughout testing, demonstrating that the bed serves as a good heat sink for the gasification process. Product syngas temperature measured above the bed was stable at ~1600ºF. Testing found that syngas quality measured as H 2 /CO ratio increased with decreasing oxygen to fuel gas stoichiometric ratio, higher steam to inlet carbon ratio, higher temperature, and syngas compared with natural gas. The highest H 2 /CO ratios achieved were in the range of 0.70 to 0.78. These values are well below the targets of 1.5 to 2.0 that were expected and were predicted by modeling. The team, however, is encouraged that the HMB process can and will achieve H 2 /CO ratios up to 2.0. Changes needed include direct injection of coal into the molten bed of slag to prevent coal particle bypass into the product gas stream, elevation of the molten bed temperature to approximately 2500ºF, and further decrease of the oxygen to fuel gas ratio to well below the 0.85 minimum ratio used in the testing in this project.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2016

FY-2016 Methyl Iodide Higher NOx Adsorption Test Report

Deep-bed methyl iodide adsorption testing has continued in Fiscal Year 2016 under the Department of Energy (DOE) Fuel Cycle Technology (FCT) Program Offgas Sigma Team to further research and advance the technical maturity of solid sorbents for capturing iodine-129 in off-gas streams during used nuclear fuel reprocessing. Adsorption testing with higher levels of NO (approximately 3,300 ppm) and NO2 (up to about 10,000 ppm) indicate that high efficiency iodine capture by silver aerogel remains possible. Maximum iodine decontamination factors (DFs, or the ratio of iodine flowrate in the sorbent bed inlet gas compared to the iodine flowrate in the outlet gas) exceeded 3,000 until bed breakthrough rapidly decreased the DF levels to as low as about 2, when the adsorption capability was near depletion. After breakthrough, nearly all of the uncaptured iodine that remains in the bed outlet gas stream is no longer in the form of the original methyl iodide. The methyl iodide molecules are cleaved in the sorbent bed, even after iodine adsorption is no longer efficient, so that uncaptured iodine is in the form of iodine species soluble in caustic scrubber solutions, and detected and reported here as diatomic I2. The mass transfer zone depths were estimated at 8 inches, somewhat deeper than the 2-5 inch range estimated for both silver aerogels and silver zeolites in prior deep-bed tests, which had lower NOx levels. The maximum iodine adsorption capacity and silver utilization for these higher NOx tests, at about 5-15% of the original sorbent mass, and about 12-35% of the total silver, respectively, were lower than for trends from prior silver aerogel and silver zeolite tests with lower NOx levels. Additional deep-bed testing and analyses are recommended to expand the database for organic iodide adsorption and increase the technical maturity if iodine adsorption processes.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2017

“A System for Automatically Maintaining Pressure in a Commercial Truck Tire”

Under-inflated tires significantly reduce a vehicle’s fuel efficiency by increasing rolling resistance (drag force). The Air Maintenance Technology (“AMT”) system developed through this project replenishes lost air and maintains optimal tire cavity pressure whenever the tire is rolling in service, thus improving overall fuel economy by reducing the tire’s rolling resistance. The system consists of an inlet air filter, an air pump driven by tire deformation during rotation, and a pressure regulating device. Pressurized air in the tire cavity naturally escapes by diffusion through the tire and wheel, leaks in tire seating, and through the filler valve and its seating. As a result, tires require constant maintenance to replenish lost air. Since manual tire inflation maintenance is both labor intensive and time consuming, it is frequently overlooked or ignored. By automating the maintenance of optimal tire pressure, the tire’s contribution to the vehicle’s overall fuel economy can be maximized. The work was divided into three phases. The objectives of Phase 1, Planning and Initial Design, resulted in an effective project plan and to create a baseline design. The objectives for Phase 2, Design and Process Optimization, were: to identify finalized design for the pump, regulator and filter components; identify a process to build prototype tires; assemble prototype tires; test prototype tires and document results. The objectives of Phase 3, Design Release and Industrialization, were to finalize system tire assembly, perform release testing and industrialize the assembly process.

42 ENGINEERING↗
DOE OSTI2017

Advanced Ultrasupercritical (AUSC) Tube Membrane Panel Development

Alstom Power Inc., a wholly owned subsidiary of the General Electric Company (GE), has completed the project “Advanced Ultrasupercritical (AUSC) Tube Membrane Panel Development” under U.S. Department of Energy (DOE) Award Number DE-FE0024076. This project was part of DOE’s Novel Crosscutting Research and Development to Support Advanced Energy Systems program. AUSC Tube Membrane Panel Development was a two and one half year project to develop and verify the manufacturability and serviceability of welded tube membrane panels made from high performance materials suitable for the AUSC steam cycles, defined as high pressure steam turbine inlet conditions of 700-760°C (1292-1400°F) and 24.5-35MPa (3500-5000psi). The difficulty of this challenge lies in the fact that the membrane-welded construction imposes demands on the materials that are unlike any that exist in other parts of the boiler. Tube membrane panels have been designed, fabricated, and installed in boilers for over 50 years with relatively favorable experience when fabricated from carbon and Cr-Mo low alloy steels. The AUSC steam cycle requires membrane tube panels fabricated from materials that have not been used in a weldment with metal temperatures in the range of 582-610°C (1080-1130°F). Fabrication materials chosen for the tubing were Grade 92 and HR6W. Grade 92 is a creep strength enhanced ferritic Cr-Mo alloy and HR6W is a high nickel alloy. Once the materials were chosen, GE performed the engineering design of the panels, prepared shop manufacturing drawings, and developed manufacturing and inspection plans. After the materials were purchased, GE manufactured and inspected the tube membrane panels, determined if post fabrication heat treatment of the tube membrane panels was needed, performed pre- and post-weld heat treatment on the Grade 92 panels, conducted final nondestructive inspection of any heat treated tube membrane panels, conducted destructive inspection of the completed tube membrane panels,and performed simulated shop repairs on the panel fabricated using Grade 92. GE executed the program as the prime contractor under the direction of Principal Investigator Mr. James Pschirer. Other participants in this project included GE Boiler Engineering, GE Chattanooga Manufacturing, GE Materials Technology Center, GE Rocky Mountain Service Center, and a Technical Consultant from Electric Power Research Institute (EPRI).

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2016

Commercial Absorption Heat Pump Water Heater: Beta Prototype Evaluation

The Beta version of the Commercial Absorption Heat Pump (CAHP) water heater was evaluated in the environmental chambers at Oak Ridge National Laboratory. Ambient air conditions ranged from 17 to 75 oF and inlet water temperatures ranged from 100 to 120oF in order to capture trends in performance. The unit was operated under full fire (100%) and partial fire (55%). The unit was found to perform at 90% of the project goal at the design conditions of 47oF ambient and 100oF water temperatures. The trends across the full range of environmental conditions were as expected for ambient air temperatures above 32oF. Below this temperature and for the full fire condition, frost accumulated on the evaporator coil. In future work a defrost strategy will be enabled, the unit will be thoroughly cleaned of an oil contamination and the rectifier will be reconfigured in order to meet the design goals and have a field test unit ready in early 2017.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2017

RELAP-7 Progress Report: A Mathematical Model for 1-D Compressible, Single-Phase Flow Through a Branching Junction

In the literature, the abundance of pipe network junction models, as well as inclusion of dissipative losses between connected pipes with loss coefficients, has been treated using the incompressible flow assumption of constant density. This approach is fundamentally, physically wrong for compressible flow with density change. This report introduces a mathematical modeling approach for general junctions in piping network systems for which the transient flows are compressible and single-phase. The junction could be as simple as a 1-pipe input and 1-pipe output with differing pipe cross-sectional areas for which a dissipative loss is necessary, or it could include an active component, between an inlet pipe and an outlet pipe, such as a pump or turbine. In this report, discussion will be limited to the former. A more general branching junction connecting an arbitrary number of pipes with transient, 1-D compressible single-phase flows is also presented. These models will be developed in a manner consistent with the use of a general equation of state like, for example, the recent Spline-Based Table Look-up method [1] for incorporating the IAPWS-95 formulation [2] to give accurate and efficient calculations for properties for water and steam with RELAP-7 [3].

42 ENGINEERING↗
DOE OSTI2017

High temperature high velocity direct power extraction using an open-cycle oxy-combustion system

The implementation of oxy-fuel technology in fossil-fuel power plants may contribute to increased system efficiencies and a reduction of pollutant emissions. One technology that has potential to utilize the temperature of undiluted oxy-combustion flames is open-cycle magnetohydrodynamic (MHD) power generators. These systems can be configured as a topping cycle and provide high enthalpy, electrically conductive flows for direct conversion of electricity. This report presents the design and modeling strategies of a MHD combustor operating at temperatures exceeding 3000 K. Throughout the study, computational fluid dynamics (CFD) models were extensively used as a design and optimization tool. A lab-scale 60 kWth model was designed, manufactured and tested as part of this project. A fully-coupled numerical method was developed in ANSYS FLUENT to characterize the heat transfer in the system. This study revealed that nozzle heat transfer may be predicted through a 40% reduction of the semi-empirical Bartz correlation. Experimental results showed good agreement with the numerical evaluation, with the combustor exhibiting a favorable performance when tested during extended time periods. A transient numerical method was employed to analyze fuel injector geometries for the 60-kW combustor. The ANSYS FLUENT study revealed that counter-swirl inlets achieve a uniform pressure and velocity ratio when the ports of the injector length to diameter ratio (L/D) is 4. An angle of 115 degrees was found to increase distribution efficiency. The findings show that this oxy-combustion concept is capable of providing a high-enthalpy environment for seeding, in order to render the flow to be conductive. Based on previous findings, temperatures in the range of 2800-3000 K may enable magnetohydrodynamic power extraction. The heat loss fraction in this oxy-combustion system, based on CFD and analytical calculations, at optimal operating conditions, was estimated to be less than 10 percent. Furthermore, the heat transfer design removed approximately 7 MW/m2. The results observed in the lab-scale system were employed to develop a 1-MW scaled prototype. Scaling methods were based on critical design criteria found in similar systems, aimed at replicating combustion flow fields and reducing possible instabilities. A numerical simulation of the combustor wall was developed for a combined thermal steady model and static structural model. This combined model was developed predict combined stress parameters within the wall during testing conditions. Both models were developed within ANSYS FEA software package. The relative accuracy presented as well major performance parameters are discussed to assess the design's validity and ensure safety. The scaled prototype was manufactured through selective laser melting (SLM)-based additive manufacturing to reduce lead times and increase geometrical complexity. Additional CFD models were developed to optimize coolant manifold system parameters and perform a parametric study on channel geometry. An investigation on coolant manifold geometry demonstrated improvements in channel flow distribution when enlarging manifold lengths and increasing the number of tubes feeding into the flow. A three-dimensional model based on a single channel was developed to capture the effect of variable properties and thermal stratification. All cases in the simulation exhibited higher wall temperatures and lower convective coefficients than those determined through 1-D analytical equations. This implies that pressure and velocity safety factors must be implemented during system operation. Overall, the findings made in this investigation are thought to be of value to researchers and industrial practitioners when designing oxy-fuel direct power extraction systems operating at temperatures exceeding 3000 K. In addition to this, the implementation of the developed technology at pilot and commercial scales could result in a significant improvement in the efficiencies of heritage and next-generation power cycles.

03 NATURAL GAS↗