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All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

First Examination of Irradiated Fuel with Pulsed Neutrons at LANSCE (Preliminary Results)

We present preliminary results on the characterization of an irradiated U-lOZr-lPd fuel sample that was prepared from the irradiated AFC-3A-R5A sample. U-lOZr metallic fuels are researched as host materials for potential transmutation fuels and the addition of palladium strives to bind lanthanides, thus preventing fuel-cladding chemical interactions (FCCI). These interactions limit the lifetime of metallic fuels and are caused by migration of lanthanide fission products to the periphery of the fuel slug, where they start to interact with the D9 or HT9 steel cladding, ultimately leading to failure of the mechanical integrity of the cladding. Neutrons offer bulk characterization of irradiated materials for which X-ray tomography methods are not suitable due to the immense gamma background emitted from the samples. In particular pulsed neutrons provide information from the ability to resolve the neutron energy using their time-of-flight and thus the potential to utilize neutron absorption resonance to characterize the spatial distribution of isotopes. This, in turn, may allow to characterize the distribution of fission and neutron capture products non-destructively and may ultimately be applied to the bulk of an irradiation capsule prior to destructive post-irradiation examination to identify regions of interest. To allow the characterization of entire irradiation capsules, a cask is under development in the advanced post-irradiation work package at LANL and progress on this development was reported elsewhere. In parallel, an irradiated U-lOZr-lPd sample cut from the AFC-3AR5A irradiation was shipped to LANL and will be fully characterized with an NSUF funded rapid turnaround experiment (RTE) in the 2020 LANSCE run cycle. The sample emits at a dose rate of ~3R/hr on contact and is therefore manageable with remote handling, without requiring a cask. The disk-shaped material is larger than samples prepared for analysis using electron or X-ray methods and is therefore an intermediate step towards characterization of bulk samples at LANSCE. However, since it covers the full diameter of the irradiated fuel slug, some insight on redistribution of elements, spatially resolved information on microstructure, e.g. phase composition and texture, will be possible using the pulsed neutron-based methods developed for fuel characterization at LANSCE. This report describes the development of procedures to handle the sample at LANSCE as well as preliminary data and results from tests conducted in December 2019 on the energy-resolved neutron imaging (ERNI) beam line at flight path 5 and the high pressure-preferred orientation diffractometer (HIPPO) at LANSCE. This effort is a collaboration between LANL, INL, and ORNL. To compare our capabilities with prior work, we present an overview of previously reported bulk characterization of irradiated or spent fuels. The overview addresses neutron diffraction and neutron absorption resonance spectroscopy, both of which have only few reported applications on irradiated or spent nuclear fuel, as well as neutron radiography. This literature review was already described in a previous report but is repeated here to put our current efforts in context of previous work.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

PNNL's Characterization Summary for MP-2 Experiment

Characterization of as-fabricated fuel was performed at Pacific Northwest National Laboratory (PNNL) in accordance with the characterization plan for the fabrication of U 10Mo plate fuel for the U.S. High Performance Research Reactor conversion program’s Fuel Fabrication Pillar (INL 2021). Similar characterization work is also being performed at Idaho National Laboratory to provide a detailed understanding of the as-fabricated foils that would be irradiated in the Mini-Plate 2 (MP 2) experiment. Under the MP 2 characterization plan, foils are studied that have different fabrication parameters (such as rolling condition, rolling thickness reduction, co-rolling with Zr layers). Similar samples from master foils were sent to both the organizations, so that the testing and analysis can be done independently using similar equipment and standardized measurement and analysis procedures. A final, consolidated report will be prepared based on this work and will summarize all the information obtained from the two laboratories. The MP 2 experiment will provide an opportunity to understand the effects of processing conditions on the final fuel microstructure, to compare results obtained independently, and achieve a two-way validation. In Fiscal Year 2022, PNNL received five MP 2 cast (PD STD2) samples to examine the foils’ chemistry and microstructure. For each cast sample, PNNL received samples from three different locations. PNNL also received and characterized 24 U 10Mo foil samples, by sectioning four pieces/specimens from each foil, in accordance with the MP 2 Characterization Plan (INL 2021). These 24 samples consist of four types of foils from BWX Technologies: 0.047 in. thick hot-rolled and annealed samples with Zr layers; 0.025 in. thick cold-rolled and annealed samples with Zr layers; 0.0105 in. thick cold-rolled and annealed samples with Zr layers. Along with these, PNNL also received four plates with Zr layers that were 0.025 in. and 0.0105 in. thick. This report describes the results of PNNL’s MP 2 foil characterization. Microstructure, Mo homogeneity, carbide fraction and morphology, U 10Mo foil thickness, and Zr thickness were evaluated in both the longitudinal and transverse directions for all the foils of the three different thicknesses.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

Experience with Chemical Looping Combustion of Coal in a 200 kW Dual Fluidized Bed Reactor

The University of Utah recently commissioned a dual fluidized bed process development unit (PDU) for investigating chemical looping combustion (CLC) and chemical looping with oxygen uncoupling (CLOU) of coal. The reactors and supporting systems were sized to support at least 200 kW of coal input based on available reaction rate data. Both the air reactor and fuel reactor are circulating fluidized beds and bed material passes between the reactors via loop seals. The reactors are refractory-lined rather than electrically heated, so the system must be preheated with natural gas before chemical looping combustion can begin. Air and steam are preheated through a combination of electric heating and natural gas burners and reactor product gas flows through heat exchangers and bag houses to cool and clean the gas of particulate. As is typical with pilot-scale systems, several operational challenges were encountered as the system was brought online and operation progressed from heatup and initial testing with gaseous fuels towards full CLOU processing of coal. The system hardware and operational procedures have undergone several modifications, but the PDU can now reliably be preheated to the operating temperature and coal can be fed at the target feed rate. This paper presents the PDU, describes the procedures for evaluating carbon conversion, CO2 capture and CO2 purity, and presents initial results from chemical looping combustion of coal with non-CLOU and CLOU carriers. General experience of operating the plant and notable challenges and solutions are also presented.

Whitty, Kevin J.↗
DOE OSTI2016

Verification of BOUT++ by the method of manufactured solutions

BOUT++ is a software package designed for solving plasma fluid models. It has been used to simulate a wide range of plasma phenomena ranging from linear stability analysis to 3D plasma turbulence and is capable of simulating a wide range of drift-reduced plasma fluid and gyro-fluid models. A verification exercise has been performed as part of a EUROfusion Enabling Research project, to rigorously test the correctness of the algorithms implemented in BOUT++, by testing order-of-accuracy convergence rates using the Method of Manufactured Solutions (MMS). We present tests of individual components including time-integration and advection schemes, non-orthogonal toroidal field-aligned coordinate systems and the shifted metric procedure which is used to handle highly sheared grids. The flux coordinate independent approach to differencing along magnetic field-lines has been implemented in BOUT++ and is here verified using the MMS in a sheared slab configuration. Finally, we show tests of three complete models: 2-field Hasegawa-Wakatani in 2D slab, 3-field reduced magnetohydrodynamics (MHD) in 3D field-aligned toroidal coordinates, and 5-field reduced MHD in slab geometry.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2019

Assessment of InSb infrared detector arrays assembly procedure employing ANSYS

Local failure in the InSb infrared detector arrays (InSb IDAs) is chiefly triggered by the local shear stress, the peeling stress, and the tensile stress in the InSb IDAs. Thus, these three stress components are utilized to assess the rationality of the current assembly procedure of the InSb IDAs in this paper, which is described as follows: firstly, performing liquid nitrogen shocking tests on the fabricated InSb IDAs, provided that no local failure phenomena occur in the InSb IDAs, then the balanced composite structure (BCS) is glued with the bottom surface of the InSb IDAs to accomplish the fabrication of the InSb IDAs assembly. We ascertain that the tensile stress in the center region of the InSb substrate declines slightly with the attached BCS, at the same time, both the interfacial shear stress and the peeling stress maintain unchanged at the locations where the local delamination most likely appears. These non-increased stress distribution characteristics with the added BCS confirmed that the current assembly procedure of the InSb IDAs is reasonable, and the glued BCS does not increase the failure probability of the InSb IDAs assembly.

36 MATERIALS SCIENCE↗
DOE OSTI2017

Pilot-Scale Silicone Process for Low-Cost Carbon Dioxide Capture. Final Scientific/Technical Report

GE Global Research has developed, over the last 8 years, a platform of cost effective CO 2 capture technologies based on a non-aqueous aminosilicone solvent (GAP-1m). As demonstrated in a previous funded DOE project (DE-FE0007502), the GAP-1m solvent has increased CO 2 working capacity, lower volatility and corrosivity than the benchmark aqueous amine technology. The current report describes the cooperative program between GE Global Research (GE GRC), and the National Carbon Capture Center (NCCC) to design, construct, and operate a pilot-scale process using GAP-1m solvent to demonstrate its performance at 0.5 MWe. (i) Performance of the GAP-1m solvent was demonstrated in a 0.5 MWe pilot with real flue gas for over 900 hrs. of operation using two alternative desorption designs: a Continuous Stirred Tank Reactor (CSTR), and a Steam Stripper Column (SSC). The CSTR is a one-stage separation unit with reduced space requirements, and capital cost. The alternative is a multi-stage separation column, with improved desorption efficiency. Testing the two desorber options allowed us to identify the most cost effective, and space efficient desorber solution. (ii) CSTR Campaign: The CSTR desorber unit was designed, fabricated and integrated with the pilot solvent test unit (PSTU), replacing the PSTU Steam Stripper Column at NCCC. Solvent management and waste water special procedures were implemented to accommodate operation of the non-aqueous solvent in the PSTU. Performance of the GAP-1m solvent with the CSTR was demonstrated for over 500 hrs. while varying temperature of the desorption (230 – 265 oF), solvent circulation rate (GAP-1m : CO 2 (molar) = 1.5 – 4), and flue gas flow rates (0.2 – 0.5 MWe). Solvent carry-over in the CO 2 product was minimized by maintaining water content below 5 wt.%, and desorption pressure at 7 psig. CO 2 capture efficiency achieved was 95% at 0.25 MWe (GAP-1m : CO 2 = 4 (molar), 230 oF desorption), and 65% at 0.5 MWe (GAP-1m : CO 2 (molar) = 1.5, 248 oF). Solvent loss was dominated by thermal degradation of the rich solvent. (iii) Steam Stripper Column Campaign: Higher expected cost of the solvent vs. aqueous amines makes solvent management a top priority to maintain the low cost for the process. During the testing of the GAP-1m solvent with the CSTR, thermal degradation of the rich solvent was found to be the main mechanism in solvent loss. Small amounts of water in the working solution were found to be an effective way to enable steam stripping, thereby lowering desorption temperature, and hence reducing thermal degradation. Steam stripping also increased working capacity by 30% due to a more efficient desorption. The concept was first tested in a glass stripping column (lab scale, GE GRC), optimized in a continuous bench scale system (2 kWe, GE GRC), and demonstrated in a 0.5 MWe PSTU at NCCC. No special system modifications were required to the PSTU to accommodate the testing of the non-aqueous GAP-1 solvent with the regenerator column. SSC was found to be more robust towards solvent entrainment (H 2 O < 35 wt.%). 90 – 95% CO 2 capture efficiency was achieved under stoichiometric conditions at 0.5 MWe (235 oF desorption, 2 psig and 19 wt. % H 2 O). Both CO 2 capture efficiency and specific duty reached optimum conditions at 18 wt.% H 2 O. Low amine degradation (< 0.05 wt.%/day) was recorded over 350 hrs. of operation. Controlled water addition to GAP-1m solvent decreased the desorption temperature, thermal degradation, and improved the CO 2 working capacity due to more efficient absorption and desorption processes. Under these conditions, the GAP-1m solvent exhibited a 25% increased working capacity, and 10% reduction in specific steam duty vs. MEA, at 10 oF lower desorption temperature. (iv) Techno-economic Analysis: The pilot-scale PSTU engineering data were used to update the capture system process models, and the techno-economic analysis was performed for a 550 MW coal fired power plant. The 1st year CO 2 removal cost for the aminosilicone-based carbon-capture process was evaluated at $48/ton CO 2 using the steam stripper column. This is a 20% reduction compared to MEA, primarily due to lower overall capital cost. CO 2 cost using the CSTR desorber is dominated by the economics of the solvent make-up. The steam stripper desorber is the preferred unit operation due to a more efficient desorption, and reduced solvent make-up rate. Further reduction in CO 2 capture cost is expected by lowering the manufacturing cost of the solvent, implementing flowsheet optimization and/or implementing the next generation aminosilicone solvent with improved stability and increased CO 2 working capacity.

0.5 MW Pilot↗
DOE OSTI2016

Experimental Activities with the IELLLO Lithium-Lead Facility

Fusion power offers the prospect of an almost inexhaustible source of energy for future generations. Although this may be true, it also presents so far serious scientific and engineering challenges. Breeding Blanket is one of key components of future fusion reactors, since it directly involves tritium breeding and energy extraction, both of them critical to development of fusion power. To deal with the development of Breeding Blankets, ENEA (Italian National Agency for New Technologies, Energy and Sustainable Economic Development) designed and built a lead lithium loop (IELLLO: Integrated European Lead Lithium Loop): the experiment aims to support R and D activities for the conceptual and preliminary design of the European test blanket systems. IELLLO was completed, installed and operated at ENEA Brasimone Research Centre. The purpose of this work is to describe the experimental activities that have been carried out concerning the qualification of the facility, and relative instrumentations, for lead lithium applications. A series of thermo-hydraulic investigations on IELLLO facility has been elaborated: lead lithium pressure transducers, heat exchanger, permanent magnet pumping system, mass flow meters and air cooler have been tested. The absolute pressure meter in contact with Pb-16Li was qualified in pressure range up to 10 bar and temperature up to 400 deg. C. The installation of new kinds of Pb-16Li differential pressure transducers will allow to check the pump characteristic curve and accurately calculate valves pressure drops. These factors could give a better information for the thermo-hydraulic qualification of the facility. Vortex Mass Flow Meter has shown good results in terms of accuracy. The performance has been validated by thermal balance with a dedicated heating system. Nevertheless, the installations of different types of mass flow meters will enable to test IELLLO at ITER relevant conditions, and at lower mass flow rates than those tested up to now. The new pumping system with a PM Pump, was qualified for the first time in Pb-16Li, and the procedure for the operation and maintenance of the pump was developed. The pump is able to supply a mass flow rate in the range from 1.2 to 2.4 kg/s with a temperature of Pb-16Li up to 550 deg. C in the test section. Significant results have been obtained also for the heat exchanger, which has shown high efficiencies, even more than expected. Likewise, the Air Cooler has been verified to be able to cool Pb-16Li in a relatively short time, even at the worst temperature and mass flow conditions. (authors)

42 ENGINEERING↗
DOE OSTI2015

2013 Caliban and Prospero experiments for the study of the behavior of radiation protection instrumentations in case of a criticality accident - 14346

Experiments using the CALIBAN and PROSPERO reactors were performed in 2013 in the framework of a collaboration between IRSN and CEA. The objective was to provide data about the possibility to use information given by radiation protection instrumentations (RPI) in the case of a criticality accident. In that purpose, the behavior of RPI was studied for various kinetics of the reactors which simulated different starts of a criticality accident. The article presents the safety issues associated with these experiments, i.e. the possible use of information given by the RPI for the emergency response of a criticality accident (detection of the accident, triage of the personnel, follow-up of the accident and reentry). Then, one paragraph is dedicated to the presentation of the tested material. In addition, the CALIBAN and PROSPERO reactors are briefly described, followed by the performed experiments. The RPI are neither designed nor dedicated to be used in case of a criticality accident. However, the preliminary conclusion of the experiments performed in 2013 is that the tested RPI have a correct behavior for slow kinetic experiments performed with the PROSPERO reactor, but might give less reliable and accurate information for pulse experiments performed with the CALIBAN reactor. In the last case, they can nevertheless provide information that can be helpful for the emergency response and the limitation of the consequences of the criticality accident. However, if the RPI are included in the emergency response of a criticality accident (detection, triage, follow-up, reentry), emergency procedures should be adapted. Other experiments might be performed in order to confirm results and to extend the number of tested materials, in particular portable survey meters or contamination area monitors. (authors)

42 ENGINEERING↗
DOE OSTI2023

Natural transformation as a tool in Acinetobacter baylyi : Streamlined engineering and mutational analysis

Natural transformation and homologous recombination in a soil bacterium, Acinetobacter baylyi ADP1, occur with exceptionally high efficiency. These genetic features can be harnessed to address a wide variety of fundamental and applied scientific topics. Recent advances in synthetic biology and laboratory evolution have led to renewed appreciation for the use of A. baylyi as a model organism. To complement several review articles that highlight new tool sets, this chapter focuses on simple protocols and examples of transformation assays that facilitate genetic analysis and engineering. Whole genome sequencing often reveals extensive genetic variation among closely related isolates that can confound the association of genotypic and phenotypic changes. In A. baylyi, such associations can be deciphered in unique ways by directly transforming cells with linear DNA fragments. The resulting allelic replacement, which occurs at high frequency, rapidly generates desired mutants via targeted chromosomal editing. Diverse screening and selection methods can be used to test hypotheses and streamline experimental strategies to reveal the significance of specific DNA sequences. Moreover, large procedural variations are well tolerated, and techniques can be readily adapted for new purposes. Furthermore, one goal of highlighting natural transformation methodology in A. baylyi is to expand the community of researchers using this versatile bacterial host.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2022

New data-driven approach to bridging power system protection gaps with deep learning

Protection is a critical function in power systems to avoid equipment damage, maintain personnel safety, and support system reliability. However, current protective relay technology cannot adequately protect equipment and personnel from effects of some events; these deficiencies are termed protection gaps. In this paper, a data-driven approach is proposed to complement traditional protection technology and distinguish fault conditions from transients caused by normal operations. A combined convolutional neural network and long short-term memory (CNN-LSTM) network is implemented to achieve data translation invariance and capture the temporal correlation of the time-series input data. As a result, the data-driven method can accurately detect system faults despite variation and noise in the input data. In addition, using the CNN-LSTM--based method avoids the complicated, manual feature extraction procedure required by many traditional data-driven methods. The effectiveness of the proposed approach is tested on two kinds of protection gaps: high-impedance faults and transformer inter-turn faults. Lastly, a transfer learning method is also proposed to address the common issue of data-driven methods for which real-world training data are scarce. Extensive study results demonstrate that the proposed approach can accurately bridge power system protection gaps.

42 ENGINEERING↗
DOE OSTI2015

Mock Quasar-Lyman-α forest data-sets for the SDSS-III Baryon Oscillation Spectroscopic Survey

We describe mock data-sets generated to simulate the high-redshift quasar sample in Data Release 11 (DR11) of the SDSS-III Baryon Oscillation Spectroscopic Survey (BOSS). The mock spectra contain Lyα forest correlations useful for studying the 3D correlation function including Baryon Acoustic Oscillations (BAO). They also include astrophysical effects such as quasar continuum diversity and high-density absorbers, instrumental effects such as noise and spectral resolution, as well as imperfections introduced by the SDSS pipeline treatment of the raw data. The Lyα forest BAO analysis of the BOSS collaboration, described in Delubac et al. 2014, has used these mock data-sets to develop and cross-check analysis procedures prior to performing the BAO analysis on real data, and for continued systematic cross checks. Tests presented here show that the simulations reproduce sufficiently well important characteristics of real spectra. These mock data-sets will be made available together with the data at the time of the Data Release 11.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2022

A deep-learning based raw waveform region-of-interest finder for the liquid argon time projection chamber

The liquid argon time projection chamber (LArTPC) detector technology has an excellent capability to measure properties of low-energy neutrinos produced by the sun and supernovae and to look for exotic physics at very low energies. In order to achieve those physics goals, it is crucial to identify and reconstruct signals in the waveforms recorded on each TPC wire. In this work, we report on a novel algorithm based on a one-dimensional convolutional neural network (CNN) to look for the region-of-interest (ROI) in raw waveforms. We test this algorithm using data from the ArgoNeuT experiment in conjunction with an improved noise mitigation procedure and a more realistic data-driven noise model for simulated events. This deep-learning ROI finder shows promising performance in extracting small signals and gives an efficiency approximately twice that of the traditional algorithm in the low energy region of ~0.03–0.1 MeV. This method offers great potential to explore low-energy physics using LArTPCs.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2015

CBP for Field Workers – Results and Insights from Three Usability and Interface Design Evaluations

Nearly all activities that involve human interaction with the systems in a nuclear power plant are guided by procedures. Even though the paper-based procedures (PBPs) currently used by industry have a demonstrated history of ensuring safety, improving procedure use could yield significant savings in increased efficiency as well as improved nuclear safety through human performance gains. The nuclear industry is constantly trying to find ways to decrease the human error rate, especially the human errors associated with procedure use. As a step toward the goal of improving procedure use and adherence, researchers in the Light-Water Reactor Sustainability (LWRS) Program, together with the nuclear industry, have been investigating the possibility and feasibility of replacing the current paper-based procedure process with a computer-based procedure (CBP) system. This report describes a field evaluation of new design concepts of a prototype computer-based procedure system.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2018

Sulfur Solubility Testing and Characterization of Hanford LAW Phase 2, Outer Layer Matrix Glasses

In this report, the Savannah River National Laboratory (SRNL) provides chemical analyses and Product Consistency Test (PCT) results for a series of simulated Low-Activity Waste (LAW) glass compositions. A procedure developed at the Pacific Northwest National Laboratory (PNNL) for producing sulfur saturated melts (SSMs) was carried out at both SRNL and PNNL to fabricate the glasses characterized in this report. This method includes triplicate melting steps with excess sodium sulfate, followed by grinding and washing to remove unincorporated sulfur salts. The wash solutions were also analyzed as part of this study. These data will be used in the development of improved property/composition models for LAW glass.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2018

Sulfur Solubility Testing and Characterization of Hanford LAW Phase 2, Outer Layer Matrix Glasses

In this report, the Savannah River National Laboratory (SRNL) provides chemical analyses and Product Consistency Test (PCT) results for a series of simulated Low-Activity Waste (LAW) glass compositions. A procedure developed at the Pacific Northwest National Laboratory (PNNL) for producing sulfur saturated melts (SSMs) was carried out at both SRNL and PNNL to fabricate the glasses characterized in this report. This method inclu des triplicate melting steps with excess sodium sulfate, followed by grinding and washing to remove unincorporated sulfur salts. The wash solutions were also analyzed as part of this study. These data will be used in the development of improved property/composition models for LAW glass.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2021

Bridging Power System Protection Gaps with Data-driven Approaches

Protection is a critical function in power systems to avoid equipment damage, maintain personnel safety, and support system reliability. However, current protective relay technology cannot adequately protect equipment and personnel from effects of some events; these deficiencies are termed protection gaps. In this research, a data-driven approach is proposed to complement traditional protection technology and distinguish fault conditions from transients caused by normal operations. A convolutional neural network (CNN) based fault detection approach is implemented to achieve data translation invariance of the time-series input data. As a result, the data-driven method can accurately detect system faults despite variation and noise in the input data. In addition, using the CNN–based method avoids the complicated manual feature extraction procedure required by many traditional data-driven methods. The effectiveness of the proposed approach is tested on four kinds of protection gaps: high impedance faults, transformer/generator inter-turn faults, distribution system PV circuit faults, and the mis-operation situations of Zone 3 line protection relays operating under system stress. Finally, a transfer learning method is also proposed to address the common issue of data-driven methods for which real-world training data are scarce. Extensive study results demonstrate that the proposed approach can accurately bridge power system protection gaps.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2021

Enhancing Steam-Side Heat Transfer via Microdroplet Ejection using Inorganic Coatings

During condensation of water on a superhydrophobic nanostructured surfaces, droplets coalesce and jump (droplet ejection) due to the release of excess surface energy. Meticulously designed nanostructured surfaces or coatings capable of droplet ejection can enhance heat transfer performance by easy removal of droplets during condensation. In the present work, the capabilities of the Nelumbo droplet ejection coatings technology currently used in commercial heat exchangers are explored and optimized for materials and conditions relevant to steam condensers. Specifically, this includes (1) adapting and optimizing the procedures and chemistries to deposit droplet ejecting coatings on materials used in the steam condenser, (2) testing of the heat transfer, durability, and fouling of the fabricated coatings under a variety of steam condenser relevant conditions, and (3) modeling of the impact of droplet dynamics and interfacial properties on heat transfer in steam condensers. We experimentally demonstrated that at low supersaturation conditions (S~1.02), developed superhydrophobic nanostructured surface gives a 40% higher peak heat transfer flux and a 17% higher peak overall heat transfer coefficient (U) with droplet ejection mechanism compared to the dropwise condensation mechanism on the same nanostructured surface. Though the experimentally observed droplet ejection mechanism was short-lived (~3 min) due to the limitation of the chiller to maintain a constant supersaturation condition in fabricated steam condenser. And large variations in water inlet temperature (+ to - 2 degrees C) caused flooding of nanostructure (Wenzel state) at higher supersaturation (S > or = 1.12). This is an important finding because typical supersaturation levels in field operation are over 1.8 and as such, either the flooding potential for these materials should be improved or operation at lower supersaturation may be required to maximize heat transfer efficiency. If supersaturation conditions can be maintained reliably in the steam condenser in addition to droplet ejection mechanism during condensation, this could provide a potential 2% reduction in water flow rate which equates to a savings of over 3900 gallons of water per minute for a 500 MW steam turbine and over $0.3MM savings annually given a 0.02 cent marginal water withdrawal cost. It is also worth noting that these savings are based on improvement of droplet ejection coatings over coatings capable of performing consistent dropwise mechanism in in-field surface condensers. Savings due to the droplet ejections coatings when compared to bare substrates could be much higher. Additionally, the present work provides the importance of steam condenser operating conditions and insights into the challenges in modeling the condensing droplet dynamics on surfaces.

20 FOSSIL-FUELED POWER PLANTS↗