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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 127 records · Page 7
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

Distinct responses of Asian summer monsoon to black carbon aerosols and greenhouse gases

Black carbon (BC) aerosols emitted from natural and anthropogenic sources induce positive radiative forcing and global warming, which in turn significantly affect the Asian summer monsoon (ASM). However, many aspects of the BC effect on ASM remain elusive and largely inconsistent among previous studies, which is strongly dependent on different low-level thermal feedbacks over the Asian continent and the surrounding ocean. This study examines the response of ASM to BC forcing in comparison with the effect of doubled greenhouse gases (GHGs) by analyzing the Precipitation Driver Response Model Intercomparison Project (PDRMIP) simulations under an extreme high BC level (10 times modern global BC emissions or concentrations, labeled by BC $\times$ 10) from nine global climate models (GCMs). The results show that although BC and GHGs both enhance the ASM precipitation minus evaporation (P–E) (a 13.6 % increase for BC forcing and 12.1 % for GHGs from the nine-model ensemble, respectively), there exists a much larger uncertainty in changes in ASM P–E induced by BC than by GHGs. The summer P–E is increased by 7.7 % to 15.3 % due to these two forcings over three sub-regions including East Asian, South Asian, and western North Pacific monsoon regions. Further analysis of moisture budget reveals distinct mechanisms controlling the increases in ASM P–E induced by BC and GHGs. The change in ASM P–E by BC is dominated by the dynamic effect due to the enhanced large-scale monsoon circulation, whereas the GHG-induced change is dominated by the thermodynamic effect through increasing atmospheric water vapor. Radiative forcing of BC significantly increases the upper-level atmospheric temperature over the Asian region to enhance the upper-level meridional land-sea thermal gradient (MLOTG), resulting in a northward shift of the upper-level subtropical westerly jet and an enhancement of the low-level monsoon circulation; whereas radiative forcing of GHGs significantly increases the tropical upper-level temperature, which reduces the upper-level MLOTG and suppresses the low-level monsoonal circulation. Hence, our results indicate a different mechanism of BC climate effects under the extreme high BC level, that BC forcing significantly enhances the upper-level atmospheric temperature over the Asian region, determining ASM changes, instead of low-level thermal feedbacks as indicated by previous studies.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2022

CODE-TO-CODE BENCHMARK STUDY FOR THERMAL STRESS MODELING AND PRELIMINARY ANALYSIS OF THE HIGH-TEMPERATURE SINGLE HEAT PIPE EXPERIMENT

Microreactors are very small nuclear reactors with typical thermal-energy output of up to 20 MWth. The microreactor concept is gaining more and more attention for safe, robust, and reliable supply of electricity for remote locations and to meet industrial process heat needs. Heat-pipe-cooled microreactor is one of the microreactors being investigated at Idaho National Laboratory. In the heat-pipe-cooled microreactor, heat pipes remove heat from the reactor core as a passive heat-transfer device, so the fluid circulation is not required for cooling, which can substantially simplify the overall reactor design. However, given the extremely high temperatures in the core region and potentially large temperature gradients across the structure materials, thermal stresses need to be well-analyzed to ensure structural integrity during normal operations and accident scenarios for the heat-pipe-cooled microreactor designs. This paper discusses finite element method-based thermal-stress analysis for the high-temperature single heat-pipe test article in the Single Primary Heat Extraction and Removal Emulator (SPHERE) facility at Idaho National Laboratory, using two commercial software packages, Abaqus and STAR-CCM+. A code-to-code benchmark study was performed to crosscheck the model setup and capability of each code and to gain insights into the potential thermal stress concerns from the current experimental setup. It is observed the significant thermal stresses happen at the locations where the largest temperature gradients appeared between heat pipe and electric heater. The temperature fields have good agreements between Abaqus and STAR-CCM+, while the induced thermal stresses show modest deviations probably due to differences of meshing engines used in these two codes.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Device for steam cladding oxidation testing at TREAT

To compare the chemical degradation of conventional zirconium alloy (Zry) cladding to advance silicon carbide (SiC) cladding in a post loss of coolant accident (LOCA) environment, new nuclear testing capabilities are necessary. The Transient Reactor Test (TREAT) Facility at Idaho National Laboratory (INL) has matured its transient fuel testing capabilities since its 2017 restart. The most recent experiment architecture is the Transient Water Irradiation System in TREAT (TWIST), which is designed to support qualification of accident tolerant fuels in light water reactors. INL has designed and analyzed a natural circulation steam flow modification for TWIST to produce prototypic conditions of cladding oxidation. The in-situ device will be electrically heated to drive natural circulation. Moreover, the SiC cladding requires heating above 1700 °C to observe failure, thus internal prototypic nuclear heating with radiation effects will be used. Thermal hydraulic analysis with RELAP5-3D (Reactor Excursion and Leak Analysis Program) estimated steam fluxes greater than 50 mg cm −2 s −1 can be achieved. These fluxes are adequate to test Zry cladding according to draft regulatory guides and to test SiC cladding according to past experiments.

Oxidation↗
DOE OSTI2022

Benchmark Specification for Select Experiments Conducted at the University of Wisconsin-Madison Thermal Stratification Test Facility

The Department of Energy (DOE)-Nuclear Energy University Programs (NEUP) supported the creation and operation of the Thermal Stratification Test Facility (TSTF) at the University of Wisconsin Madison (UWM) as part of a larger effort to understand thermal stratification behavior in liquid-metal-cooled reactors. The TSTF was designed to simulate transients in a reactor plenum that are known to cause thermal stratification. High-reliability and high-resolution measurements of the flow and temperature were collected for use as experimental benchmarks to support validation efforts for computational models. The results of these tests contribute to the greater understanding of thermal stratification behavior of liquid sodium under various configurations and operating conditions. The six TSTF tests selected for benchmarking are a set of forced circulation tests at a fixed flow rate with different Upper Internal Structure (UIS) configurations in the test section (no UIS, solid UIS, and a UIS with flow area of 4, 8, 12, and 100%). This report provides a complete description of the benchmark problems, including all key test facility details, descriptions of each test condition, and measured data for comparison with modeled results.

42 ENGINEERING↗
DOE OSTI2022

Ice-shelf ocean boundary layer dynamics from large-eddy simulations

Abstract. Small-scale turbulent flow below ice shelves is regionally isolated and difficult to measure and simulate. Yet these small-scale processes, which regulate heat and salt transfer between the ocean and ice shelves, can affect sea-level rise by altering the ability of Antarctic ice shelves to “buttress” ice flux to the ocean. In this study, we improve our understanding of turbulence below ice shelves by means of large-eddy simulations at sub-meter resolution, capturing boundary layer mixing at scales intermediate between laboratory experiments or direct numerical simulations and regional or global ocean circulation models. Our simulations feature the development of an ice-shelf ocean boundary layer through dynamic ice melting in a regime with low thermal driving, low ice-shelf basal slope, and strong shear driven by the geostrophic flow. We present a preliminary assessment of existing ice-shelf basal melt parameterizations adopted in single component or coupled ice-sheet and ocean models on the basis of a small parameter study. While the parameterized linear relationship between ice-shelf melt rate and far-field ocean temperature appears to be robust, we point out a little-considered relationship between ice-shelf basal slope and melting worthy of further study.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2023

Thermally Significant Fluid Seepage Through Thick Sediment on the Juan de Fuca Plate Entering the Cascadia Subduction Zone

We use heat flux measurements colocated with seismic reflection profiles over a buried basement high on the Juan de Fuca plate ∼25 km seaward of the deformation front offshore Oregon to test for the presence of hydrothermal circulation in the oceanic crust. We also revisit heat flux data crossing a buried basement high ∼25 km seaward of the deformation front ∼150 km north, offshore Washington. Seafloor heat flux is inversely correlated with sediment thickness, consistent with vigorous hydrothermal circulation in the basement aquifer homogenizing temperatures at the top of the basement. Heat flux immediately above the summit of the basement highs is greater than expected solely from conduction. Fluid seepage at rates of ∼2.6–5.4 cm yr −1 in a 1–1.5 km-wide conduit through ∼800–1,300 m thick sediment sections above these basement highs can explain these observations. Observations of thermally significant fluid seepage through sediment >225 m thick on oceanic crust are unprecedented. High sediment permeability, high fluid overpressure in the basement, or a combination of both is required to drive fluid seepage at the observed rates. We infer that rapid seepage occurs because the basement highs rise above the low permeability basal sediment with their tops protruding into the base of high permeability Nitinat or Astoria Fan sediment. Seepage from basement highs penetrating into the submarine fans can affect the thermal state of crust entering the subduction zone.

58 GEOSCIENCES↗
DOE OSTI2021

Spitzer Phase-curve Observations and Circulation Models of the Inflated Ultrahot Jupiter WASP-76b

The large radii of many hot Jupiters can only be matched by models that have hot interior adiabats, and recent theoretical work has shown that the interior evolution of hot Jupiters has a significant impact on their atmospheric structure. Due to its inflated radius, low gravity, and ultrahot equilibrium temperature, WASP-76b is an ideal case study for the impact of internal evolution on observable properties. Hot interiors should most strongly affect the nonirradiated side of the planet, and thus full phase-curve observations are critical to ascertain the effect of the interior on the atmospheres of hot Jupiters. In this work, we present the first Spitzer phase-curve observations of WASP-76b. We find that WASP-76b has an ultrahot dayside and relatively cold nightside with brightness temperatures of 2471 ± 27 K/1518 ± 61 K at 3.6 μm and 2699 ± 32 K/1259 ± 44 K at 4.5 μm, respectively. These results provide evidence for a dayside thermal inversion. Both channels exhibit small phase offsets of 0.68 ± 0.°48 at 3.6 μm and 0.67 ± 0.°2 at 4.5 μm. We compare our observations to a suite of general circulation models (GCMs) that consider two endmembers of interior temperature along with a broad range of frictional drag strengths. Strong frictional drag is necessary to match the small phase offsets and cold nightside temperatures observed. From our suite of cloud-free GCMs, we find that only cases with a cold interior can reproduce the cold nightsides and large phase-curve amplitude at 4.5 μm, hinting that the hot interior adiabat of WASP-76b does not significantly impact its atmospheric dynamics or that clouds blanket its nightside.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2024

Condition-Based Maintenance of a Circulating Water System of a Canadian Nuclear Power Plant using Machine Learning and Statistical Tools

Canada Deuterium Uranium pressurized-heavy-water reactors (PHWR) are a type of nuclear power plant that generate clean and reliable energy. The scope of this work is to automate data analysis methodologies to inform a condition-based maintenance strategy of a circulating water system (CWS) of a PHWR. The multiunit CWS provides a continuous supply of water to cool steam condensers, even during transient scenarios, thereby improving the thermal efficiency. This work aims to develop a machine learning (ML) based approach to detect anomalies in heterogeneous data of a CWS in a PHWR to help inform a predictive maintenance strategy. The heterogeneous data include textual and numeric time series data for a PHWR. Natural-language-processing (NLP)-based models are used to analyze textual data contained in work orders and operator logs and an event-timeseries correlation detection method is applied to assist anomalies diagnoses for CWS. An ML model Robust Linear Model (RLM) is also used to remove the seasonal variations in the system variable distributions based on distributions of environmental variables. A machine learning model, Density-Based Spatial Clustering of Applications with Noise (DBSCAN), trained on both original data and data without any seasonal variations will then be used to detect if an anomaly exists. Thus, by moving to an automated methodology to detect, classify, and forecast anomalies, the maintenance strategy would be based on component condition instead of a time-based schedule.

97 - MATHEMATICS AND COMPUTING↗
DOE OSTI2025

Life cycle assessment of a novel gas switching reforming for sustainable hydrogen production with CO2 capture

Gas switching reforming for hydrogen production (GSR-H2) presents an efficient, low-carbon hydrogen production method that incorporates integrated carbon capture, offering efficiency gains over traditional methods such as proton exchange membrane (PEM) electrolysis, steam methane reforming (SMR) and the newer method of chemical looping reforming (CLR). GSR-H2 has been demonstrated in lab scale which operates as an exothermic process that eliminates the need for additional natural gas combustion, using its own waste heat to generate process steam and partially offset energy usage through electricity production. Beyond its thermal self-sufficiency, GSR-H2 advances upon CLR by integrating all reaction stages within a single reactor cluster, eliminating the complexities of solid circulation, reducing capital costs, and enhancing overall process efficiency. This streamlined design simplifies scale-up and enables inherent CO2 separation with minimal energy penalty, making GSR-H2 a highly competitive pathway for low-carbon hydrogen production. This study presents the first life cycle assessment (LCA) of GSR-H2, offering a novel evaluation of this new process’s environmental impacts across diverse energy scenarios. Key findings reveal that in the renewables-powered scenario, GSR-H2 achieves a GWP of 2.77 kg CO2 eq per kg H2, a substantial improvement over SMR’s 10.4 kg CO2 eq and close to the low emissions of CLR (1.84 kg CO2 eq) and PEM electrolysis (1.85 kg CO2 eq). These results demonstrate GSR-H2’s competitive advantage as a lower-emission alternative, combining design simplicity and efficiency gains, especially in renewable-integrated systems. These results establish GSR-H2 as a competitive, scalable option for hydrogen production, particularly in decarbonization efforts.

03 NATURAL GAS↗
DOE OSTI2023

Design of a prototypical natural circulation water-based reactor cavity cooling system (RCCS) for a pebble-bed generic FHR

A prototypical natural circulation water-based reactor cavity cooling system (RCCS) for the UC Berkeley Mark-1 pebble-bed gFHR is designed based on one-dimensional thermal hydraulics modeling and optimization implemented in an in-house MATLAB code. The model employs a lumped core consisting of fuel pebble and graphite pebble regions, while the graphite reflector, vessel, and RCCS are represented as separate but energy-coupled regions. The model is derived based on steady state energy balance equations accounting for conductive heat transfer from the lumped core to the vessel and subsequent radiative heat transfer to the RCCS and convective heat transfer in the water. Further, mass flow rate is calculated based on momentum and thermal energy balance in the RCCS. Starting with ANL’s water NSTF as baseline, effects of RCCS design parameters such as size of the plate between pipes, pipe diameter, source-to-sink distance, surface emissivity, and pitch from the core are examined in an integral effects framework which accounts for subsequent variation of the mass flow rate, number of pipes, convection coefficient, mean region and surface temperatures, radiative view factors, and water outlet temperature. The importance of including a prototypical reactor design in RCCS design calculations is emphasized as the calculations show that temperature drops from the core to the RCCS fluid to transfer the heat tend to be the limitation not the heat removal capacity of the fluid. A closed-loop design is obtained with capability to safely remove up to 0.72% of the nominal reactor power at maximum estimated peak conditions and 0.40% at shutdown. The design is based on physics calculations and does not account for economic optimization.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2026

Stochastic fracture generation and thermo-hydro-mechanical modeling in an equivalent continuum framework for enhanced geothermal systems

Enhanced geothermal systems (EGS) involve fracturing low permeability material to establish well connectivity and then injecting and circulating fluid into the fractured subsurface for geothermal power production. Changes in fracture aperture from contraction of the cooling matrix rock may alter network connectivity and risk thermal short-circuiting. Thermo-hydro-mechanical (THM) models are a useful tool to study these processes. However, as fracture networks are complex, and data may be limited, fracture networks in THM models are often stochastically generated. Given reliance on stochastic fracture networks and THM modeling to represent the subsurface and assess productivity of EGS, increased understanding of the influence of such statistically derived fracture networks on flow and heat transport in THM models is needed. Here, a new fracture process model is developed in the reactive transport code PFLOTRAN to stochastically generate fracture families and simulate changes in fracture aperture over time due to temperature changes of the rock matrix. Sixty-four different fracture networks ranging from well to poorly-connected, are modeled in PFLOTRAN with and without mechanical processes (THM vs TH). Results indicate that for well-connected fracture networks, thermal short-circuiting is less of a concern due to the abundance of available alternative flowpaths. For poorly-connected fracture networks, inclusion of mechanical processes showed steep thermal drawdown coincident with increase in fracture aperture along developing colder flowpaths, demonstrating the risk of thermal short-circuiting. Simulations with additional, larger fractures engineered to establish connectivity in a poorly-fractured subsurface, indicate that while stochastic variation of fracture orientation of the background network had limited influence, such variation in the engineered fractures significantly affected flow and heat transport.

Discrete fracture networks (DFN)↗
DOE OSTI2021

Fracture Sustainability in Enhanced Geothermal Systems: Experimental and Modeling Constraints

Enhanced geothermal systems (EGS) offer the potential for a much larger energy source than conventional hydrothermal systems. Hot, low-permeability rocks are prevalent at depth around the world, but the challenge of extracting thermal energy depends on the ability to create and sustain open fracture networks. Laboratory experiments were conducted using a suite of selected rock cores (granite, metasediment, rhyolite ash-flow tuff, and silicified rhyolitic tuff) at relevant pressures (uniaxial loading up to 20.7 MPa and fluid pressures up to 10.3 MPa) and temperatures (150–250 °C) to evaluate the potential impacts of circulating fluids through fractured rock by monitoring changes in fracture aperture, mineralogy, permeability, and fluid chemistry. Because a fluid in disequilibrium with the rocks (deionized water) was used for these experiments, there was net dissolution of the rock sample: this increased with increasing temperature and experiment duration. Thermal-hydrological-mechanical-chemical (THMC) modeling simulations were performed for the rhyolite ash-flow tuff experiment to test the ability to predict the observed changes. These simulations were performed in two steps: a thermal-hydrological-mechanical (THM) simulation to evaluate the effects of compression of the fracture, and a thermal-hydrological-chemical (THC) simulation to evaluate the effects of hydrothermal reactions on the fracture mineralogy, porosity, and permeability. Furthermore, these experiments and simulations point out how differences in rock mineralogy, fluid chemistry, and geomechanical properties influence how long asperity-propped fracture apertures may be sustained. Such core-scale experiments and simulations can be used to predict EGS reservoir behavior on the field scale.

15 GEOTHERMAL ENERGY↗
DOE OSTI2021

Modeling of Combined Lead Fast Reactor and Concentrating Solar Power Supercritical Carbon Dioxide Cycles to Demonstrate Feasibility, Efficiency Gains, and Cost Reductions

Solar power has innate issues with weather, grid demand and time of day, which can be mitigated through use of thermal energy storage for concentrating solar power (CSP). Nuclear reactors, including lead-cooled fast reactors (LFRs), can adjust power output according to demand; but with high fixed costs and low operating costs, there may not be sufficient economic incentive to make this worthwhile. We investigate potential synergies through coupling CSP and LFR together in a single supercritical CO 2 Brayton cycle and/or using the same thermal energy storage. Combining these cycles allows for the LFR to thermally charge the salt storage in the CSP cycle during low-demand periods to be dispatched when grid demand increases. The LFR/CSP coupling into one cycle is modeled to find the preferred location of the LFR heat exchanger, CSP heat exchanger, sCO 2 -to-salt heat exchanger (C2S), turbines, and recuperators within the supercritical CO 2 Brayton cycle. Three cycle configurations have been studied: two-cycle configuration, which uses CSP and LFR heat for dedicated turbocompressors, has the highest efficiencies but with less component synergies; a combined cycle with CSP and LFR heat sources in parallel is the simplest with the lowest efficiencies; and a combined cycle with separate high-temperature recuperators for both the CSP and LFR is a compromise between efficiency and component synergies. Additionally, four thermal energy storage charging techniques are studied: the turbine positioned before C2S, requiring a high LFR outlet temperature for viability; the turbine after the C2S, reducing turbine inlet temperature and therefore power; the turbine parallel to the C2S producing moderate efficiency; and a dedicated circulator loop. While all configurations have pros and cons, use of a single cycle offers component synergies with limited efficiency penalty. Using a turbine in parallel with the C2S heat exchanger is feasible but results in a low charging efficiency, while a dedicated circulator loop offers flexibility and near-perfect heat storage efficiency but increasing cost with additional cycle components.

14 SOLAR ENERGY↗
DOE OSTI2024

National Modeling of Geothermal District Energy Systems with Ambient-Temperature Loops Using dGeo: Preprint

Geothermal district energy systems (DES) with ambient-temperature loops, also known as thermal energy networks, are one option for decarbonizing space heating and cooling loads. Geothermal fifth-generation DES include an "ambient" temperature thermal loop that connects heat pumps at each building with thermal balancing sources such as geothermal borehole fields. Heating and cooling are provided via a water-source heat pump at each end-user. This project seeks to analyze the nationwide potential for ambient-temperature loop districts by creating a new module within the Distributed Geothermal Market Demand Model (dGeo). dGeo is an agent-based modeling tool for distributed geothermal resources; it can investigate potential on a nationwide or statewide scale using geospatial data for all 50 states and thermal demands for existing buildings. This process allows for high-level estimates of technical and economic potential for ambient-temperature loop districts across the United States. Using GHEDesigner, a lookup table was created to size borehole fields for different thermal loads and ground conditions experienced across the country. A cost and financing structure, along with incentives, were applied. Cost estimates include costs for the distribution network, borehole field installation and operation, and circulation pump operation, while savings are calculated based on agent energy bills. This newly developed module can be used for assessing which areas of the country have the highest potential for agent benefits from ambient-temperature loop installation and assess the impact of different costing and pricing future scenarios. While the code is still under development and nationwide simulations are ongoing, initial results for two states are provided. Future work includes expanding the module to consider mixed residential and commercial districts and considering multiple costing scenarios.

ambient temperature loop↗
DOE OSTI2025

National Modeling of Geothermal District Energy Systems with Ambient-Temperature Loops Using dGeo

Geothermal district energy systems (DES) with ambient-temperature loops, also known as thermal energy networks, are one option for decarbonizing space heating and cooling loads. Geothermal fifth-generation DES include an "ambient" temperature thermal loop that connects heat pumps at each building with thermal balancing sources such as geothermal borehole fields. Heating and cooling are provided via a water-source heat pump at each end-user. This project seeks to analyze the nationwide potential for ambient-temperature loop districts by creating a new module within the Distributed Geothermal Market Demand Model (dGeo). dGeo is an agent-based modeling tool for distributed geothermal resources; it can investigate potential on a nationwide or statewide scale using geospatial data for all 50 states and thermal demands for existing buildings. This process allows for high-level estimates of technical and economic potential for ambient-temperature loop districts across the United States. A lookup table was created using GHEDesigner to size borehole fields for different thermal loads and ground conditions experienced across the country. A cost and financing structure, along with incentives, were applied. Cost estimates include costs for the distribution network, borehole field installation and operation, and circulation pump operation, while savings are calculated based on energy bills for building owners (agents). This newly developed module can be used for assessing which areas of the country have the highest potential for agent benefits from ambient-temperature loop installation and assess the impact of future cost and price scenarios. Initial results for statewide analysis (for Vermont) and nationwide (for United States) are provided. Future work includes expanding the module to consider mixed residential and commercial districts as well as evaluating multiple cost scenarios.

ambient-temperature loop↗
DOE OSTI2025

Simulations of the fault current limiting operation of a long-length REBCO CORC ® superconducting cable cooled by helium gas

Conductor-on-round-core (CORC®) cables composed of rare-earth-barium-copper-oxide high-temperature superconducting (HTS) tapes are of great interest for power transmission applications due to their many advantages such as high power density, light weight, and low loss. Closed circulation loops of cryogenic helium gas can be used to cool HTS cables down to low temperatures to significantly improve their current-carrying capacity. Coupled circuit-electromagnetic-thermal finite element simulations implemented in the COMSOL Multiphysics package were developed, validated, and then used for simulating the fault current limiting (FCL) performance and the cooling processes of an 8-layer CORC® cable cooled with a flow of cryogenic helium gas. In the simulations, the temperature dependence of the electrical and thermal properties of all component materials is implemented for improved accuracy. To overcome computational challenges caused by the considerable difference in geometrical scales (i.e. few-µm-thick HTS layers versus 10 m-long HTS cable), the model is divided into two separate simulations. The first simulation is performed on the transverse cross-section of the cable to calculate the electric field, heating power and temperature rise in each component of a CORC® cable during FCL operation. The heating power calculated in the first simulation is transferred to the second model to simulate the cooling of a 10 m-long cable after the fault is cleared. The effect of the helium gas flow rate on the cooling process is also investigated to develop strategic approaches for optimizing cooling systems for HTS cables with FCL capability. The simulations indicated that a 40 ms fault with a voltage drop of 20 V m −1 along the cable can result in a temperature increase from 60 K to about 165 K inside the cable, and it takes about 500 s to cool the cable back to nearly 60 K with a flow of cold helium gas at a rate of 5 g s −1 .

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2026

Development of a Test-Bed for Testing and Refining EarthEn’s Supercritical CO 2 Based Energy Storage System

EarthEn’s energy storage concept leverages supercritical carbon dioxide (sCO 2 ) as a working fluid and relies on compact, high-performance components operating at elevated pressures and temperatures. To accelerate component development and reduce technical risk prior to larger-scale demonstrations, Oak Ridge National Laboratory (ORNL) developed a 100 kW-scale sCO 2 test-bed under a Cooperative Research and Development Agreement with EarthEn (CRADA NO. NFE-24-10050). The objective of the work was to design and construct a flexible experimental facility capable of reproducing key thermodynamic state points and heat-transfer conditions relevant to EarthEn’s thermal energy storage (TES) cycle, with particular emphasis on enabling development and evaluation of next-generation heat exchangers and TES concepts. The test-bed consists of a closed-loop sCO 2 circulation system housed within an open-topped enclosure. In its as-installed configuration, dense-phase sCO 2 is recirculated through a printed circuit recuperator, an electrically heated section, a throttling device used to simulate turbine expansion, and a water-cooled printed circuit heat exchanger that rejects heat to the building chilled-water system before returning to the pump. The pump is driven by a variable frequency drive, enabling controlled adjustment of flow and operating point. A comprehensive instrumentation suite was integrated to support both safe operation and high-quality data collection. Installed sensors include Coriolis flow meters for sCO 2 flow rate and density, resistance temperature detectors and thermocouples distributed throughout the loop (including the heated section and key heat exchanger ports), and pressure transducers for absolute and differential pressure measurements. The facility was designed to support high-pressure (19 MPa nominal) and high-temperature (575°C nominal) operation with credited overpressure protection provided by a rupture disk. Nominal operating conditions were selected to support 100 kW-class testing while maintaining flexibility for non-heated and heated shakedown, control development, and future integration of advanced TES test sections. In parallel with facility development, a system-level thermal-hydraulic model was created using Modelica-based tools to support component sizing, anticipate performance over targeted test conditions, and establish a framework for future model calibration against experimental data. At the conclusion of the project performance period, the facility was in final assembly, and the pressure boundary was nearly completed. However, several practical challenges associated with high-pressure/high-temperature systems and specialized component procurement impacted schedule and prevented initial pump-driven operation and full commissioning within the available resources. This report documents the as-built design, operating capabilities, and instrumentation, and it summarizes key lessons learned related to heater fabrication and testing, first-of-a-kind assembly factors, specialty flange supply constraints, and fill pump corrective actions. Finally, it outlines a phased plan for future commissioning and experimental campaigns, including control and instrumentation shakedown, heater characterization, model calibration, and testing at state points representative of EarthEn’s TES cycle.

25 ENERGY STORAGE↗