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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

Multi-scale dynamics of magnetic flux tubes and inverse magnetic energy transfer

Here, we report on an analytical and numerical study of the dynamics of a three-dimensional array of identical magnetic flux tubes in the reduced-magnetohydrodynamic description of the plasma. We propose that the long-time evolution of this system is dictated by flux-tube mergers, and that such mergers are dynamically constrained by the conservation of the pertinent (ideal) invariants, viz. the magnetic potential and axial fluxes of each tube. We also propose that in the direction perpendicular to the merging plane, flux tubes evolve in a critically balanced fashion. These notions allow us to construct an analytical model for how quantities such as the magnetic energy and the energy-containing scale evolve as functions of time. Of particular importance is the conclusion that, like its two-dimensional counterpart, this system exhibits an inverse transfer of magnetic energy that terminates only at the system scale. We perform direct numerical simulations that confirm these predictions and reveal other interesting aspects of the evolution of the system. We find, for example, that the early time evolution is characterized by a sharp decay of the initial magnetic energy, which we attribute to the ubiquitous formation of current sheets. We also show that a quantitatively similar inverse transfer of magnetic energy is observed when the initial condition is a random, small-scale magnetic seed field.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2020

Shape-Shifting Peptide Nanomaterials: Surface Asymmetry Enables pH-Dependent Formation and Interconversion of Collagen Tubes and Sheets

The fabrication of dynamic, transformable biomaterials that respond to environmental cues represents a significant step forward in the development of synthetic materials that rival their highly functional, natural counterparts. In this work, we describe the design and synthesis of crystalline supramolecular architectures from charge-complementary heteromeric pairs of collagen-mimetic peptides (CMPs). Under appropriate conditions, CMP pairs spontaneously assemble into either 1D ultraporous (pore diameter >100 nm) tubes or 2D bilayer nanosheets due to the structural asymmetry that arises from heteromeric self-association. Crystalline collagen tubes represent a heretofore unobserved morphology of this common biomaterial. In-depth structural characterization from a suite of biophysical methods, including TEM, AFM, high-resolution cryo-EM, and SAXS/WAXS measurements, reveals that the sheet and tube assemblies possess a similar underlying lattice structure. The experimental evidence suggests that the tubular structures are a consequence of the self-scrolling of incipient 2D layers of collagen triple helices and that the scrolling direction determines the formation of two distinct structural isoforms. Furthermore, we show that nanosheets and tubes can spontaneously interconvert through manipulation of the assembly pH and systematic adjustment of the CMP sequence. Altogether, we establish initial guidelines for the construction of dynamically responsive 1D and 2D assemblies that undergo a structurally programmed morphological transition.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Spontaneous imbibition in a square tube with corner films: theoretical model and numerical simulation

Spontaneous imbibition in an angular tube with corner films is a fundamental problem in many scientific and engineering processes. In this paper, a modified interacting capillary bundle model is developed to describe the liquid imbibition dynamics in a square tube with corner films. The square tube is decomposed into several interacting sub-capillaries and the local capillary pressure in each sub-capillary is derived based on the specific shape of its meniscus. The conductance of each sub-capillary is calculated using single-phase lattice Boltzmann simulation. The modified interacting capillary bundle model and color-gradient lattice Boltzmann method are used to simulate the liquid imbibition dynamics in the square tube with different fluid properties. The predictions by the modified interacting capillary bundle model match well with the lattice Boltzmann simulation results for different conditions, demonstrating the accuracy and robustness of the interacting capillary bundle model to describe the imbibition dynamics with corner films. In addition, the interacting capillary bundle model is helpful to investigate the mechanisms during spontaneous imbibition and the influences of fluid viscosity, surface tension, wetting phase contact angle and gravity on imbibition dynamics. Finally, a universal scaling law of imbibition dynamics for the main meniscus is developed and the scaling law for arc meniscus is also analyzed.

42 ENGINEERING↗
DOE OSTI2021

Enhanced condensation heat transfer using porous silica inverse opal coatings on copper tubes

Abstract Phase-change condensation is commonplace in nature and industry. Since the 1930s, it is well understood that vapor condenses in filmwise mode on clean metallic surfaces whereas it condenses by forming discrete droplets on surfaces coated with a promoter material. In both filmwise and dropwise modes, the condensate is removed when gravity overcomes pinning forces. In this work, we show rapid condensate transport through cracks that formed due to material shrinkage when a copper tube is coated with silica inverse opal structures. Importantly, the high hydraulic conductivity of the cracks promote axial condensate transport that is beneficial for condensation heat transfer. In our experiments, the cracks improved the heat transfer coefficient from ≈ 12 kW/m 2 K for laminar filmwise condensation on smooth clean copper tubes to ≈ 80 kW/m 2 K for inverse opal coated copper tubes; nearly a sevenfold increase from filmwise condensation and identical enhancement with state-of-the-art dropwise condensation. Furthermore, our results show that impregnating the porous structure with oil further improves the heat transfer coefficient by an additional 30% to ≈ 103 kW/m 2 K. Importantly, compared to the fast-degrading dropwise condensation, the inverse opal coated copper tubes maintained high heat transfer rates when the experiments were repeated > 20 times; each experiment lasting 3–4 h. In addition to the new coating approach, the insights gained from this work present a strategy to minimize oil depletion during condensation from lubricated surfaces.

Adera, Solomon↗
DOE OSTI2024

Shock tube experiments on the three-layer Richtmyer–Meshkov instability

Here, a vertical shock tube is used for experiments on the three-layer Richtmyer–Meshkov instability. Two closely spaced membrane-less interfaces are formed by the flow of two different sects of three gases: one with air above CO 2 above SF 6 and the other with helium above air above SF 6 . The lightest of the three gases enters the shock tube at the top of the driven section and flows downward. Conversely, the heaviest gas enters at the bottom of the shock tube and flows upward while the intermediate density gas enters at the middle through porous plates. All three gases are allowed to escape through holes at the layer location, leaving an approximately 30-mm layer of intermediate-density gas suspended between the lightest gas from above and the heaviest gas from below. A single-mode, two-dimensional initial perturbation is then imposed on the lower interface by oscillating the shock tube in the horizontal direction. The flow is visualized by seeding the intermediate gas with particles and illuminating it with a pulsed laser. Image sequences are then captured using high-speed video cameras. Perturbation amplitude measurements are made from the three-layer system and compared with measurements from 2, two-layer systems. It is observed that the presence of the upper, initially flat interface produces a decrease in growth of instability amplitude in the nonlinear phase over an equivalent single-interface configuration.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2025

Numerical simulation of frost formation and heat transfer on fin-and-tube heat exchangers in turbulent cross-flow

Frost formation in fin-and-tube heat exchangers in turbulent cross-flow presents significant challenges in industrial refrigeration applications, affecting heat transfer efficiency and operational reliability. The purpose of this work is to investigate frost deposition and growth on a staggered bank of a fin-and-tube freezer coil under turbulent forced convection conditions. The focus here is on investigating conditions that closely replicate real-world scenarios in large walk-in industrial freezers. Using a direct numerical simulation approach, we examine the flow dynamics and thermal behaviour in the presence of frost, considering turbulent regimes characterized by a Reynolds number in the range 1050 ≤ R e D , avg ≤ 4800 , with the characteristic length being the outer diameter of the tube and the velocity being the bulk fluid velocity between the plates (fins). Computational fluid dynamics simulations are employed to resolve the interactions between turbulent airflow and the frost layer. Our approach incorporates a modified immersed boundary method and a slow-time acceleration technique to address the complex dynamic interface between the continuously evolving frost layer and the flowing air stream. Our findings indicate that frost forms more on the sides of the finned surfaces (plates) and less on the tubes themselves. This article is part of the theme issue ‘Heat and mass transfer in frost and ice’.

Science & Technology - Other Topics↗
DOE OSTI2023

STRESS AND FATIGUE ANALYSIS OF AIR-TO-REFRIGERANT HEAT EXCHANGERS WITH NON-ROUND TUBE SHAPES

Air-to-refrigerant heat exchangers are fundamental components in Heating, Ventilation, Air Conditioning, and Refrigeration (HVAC&R) systems. Recent research has shown that heat exchangers utilizing small hydraulic diameter, non-round, shape-optimized tubes to be promising next design update. Such tubes can improve performance, reduce material and lower refrigerant charge. However, such tube designs may be more susceptible to fatigue issues. Therefore, stress and fatigue analyses of such heat exchangers are critical to ensure structural integrity, reliability, and manufacturability. In the present work, a mechanical model is developed to obtain the stress distributions in heat exchangers with round, ellipse, and airfoil-shaped tubes. The results indicate that under 3.45 MPa internal pressure, the maximum stresses don't surpass 190 MPa.

Zhang, Mingkan↗
DOE OSTI2022

Experimental Investigation of Polymer-Induced Fouling of Heater Tubes in the First-Ever Polymer Flood on Alaska North Slope Part II

A polymer flood pilot has been ongoing in the Schrader Bluff viscous oil reservoir at Milne Point on the Alaska North Slope. The results from the pilot are encouraging. However, a major concern of the operator is the influence of polymer on the production system after breakthrough, especially the fouling in heat exchangers. This work applies a multiexperimental approach to study the severity of polymer-induced fouling in both dynamic and static states of produced fluids to determine safe operating conditions. Dynamic scale loop (DSL) tests were conducted to study fouling due to polymer at different skin temperatures (165–350°F) in a dynamic state of fluid flow where the fluids’ flow mimics the residence time of fluids in the heat exchanger of the field pilot. Static deposit tests were also conducted at similar skin temperatures of 165–250°F using a novel experimental apparatus designed and built in-house. It was found that at higher skin temperatures of 250–350°F, tube blocking was observed in the DSL tests, whereas the tests at 165–200°F did not show any tube blocking, even in a more extended test period. The deposit test showed that the deposit rate generally increases with skin temperature, and the presence of polymer aggravates the fouling. The copper tube performs best when the skin temperatures are 165–200°F, while the stainless steel tube performs best at a skin temperature of 250°F. These experiments also manifested the influence of the cloudpoint of the solution as the deposit rate increased significantly when the skin temperature was higher than the solution cloudpoint. The study provides a source of practical guidance to the field operations.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Modeling Study of Reduced Tubing Size Effects on Flow in Depleted Reservoir Natural Gas Storage Wells

This report explores the effects of tubing size reductions on natural gas flow from representative depleted reservoir underground storage wells and fields using basic models for coupled reservoir and pipe flow. This work was motivated by interest at the U.S. Department of Transportation, Pipeline and Hazardous Materials Safety Administration, in evaluating the effects of tubing and packer as a potential safety upgrade to implement double-barrier systems to existing underground natural gas storage wells. Reservoir and well flow models were developed from widely accepted industry equations, verified against a commercial process simulator model, and validated against field data. The study utilized U.S. operator survey data to provide context and assure that modeling parameters including aver age deliverability rates for wells and fields, operating pressures, well depths, and storage capacities were all carefully considered to keep the modeling relevant to the known range of U.S. operations. The models generally found that wells and fields with inherently low deliverability were relatively insensitive to reductions in tubing diameter, primarily because the hydraulics in those cases were controlled by reservoir properties. For the high-producing wells and fields, the models found that reducing tubing diameter could produce significant reductions in deliverability, both at the field- and well-level. When put into context with occurrence data regarding average deliverability of fields and wells, it appears that most wells and most fields across the U.S. would experience deliverability reductions on the low end of what was simulated here, generally below 20%. For fields with moderate to high deliverability, reductions were generally larger, and could reach as high as 60% for the highest-producing wells and fields.

03 NATURAL GAS↗
DOE OSTI2022

High-Temperature Tensile and Creep Test Results on Thin Wall Tube Specimens of ODS Alloys 14YWT and OFRAC

High-temperature tensile and strain rate jump (SRJ) creep tests were conducted on axial specimens fabricated from thin wall tubes of the oxide dispersion strengthened (ODS) alloys 14YWT and OFRAC. The dimensions of the 14YWT thin wall tube was 10.7 mm OD, 0.5 mm WT and 0.92 m and of the OFRAC thin wall tube was 8.5 mm OD + 0.5 mm WT and 1.78 m in length. The axial specimens fabricated from the thin wall tubes were based on a dual-gauge design with gauge dimensions of 4 mm long and 2 mm wide. The tensile tests were conducted in air at 800ºC, 900ºC and 1,000ºC and the SRJ creep tests were conducted in air at 800ºC. Two axial specimens were used in each tensile and SRJ creep tests. The results of the tensile tests showed much lower yield stress (YS) compared to ultimate tensile strength (UTS) indicative of large work hardening properties. The results showed the UTS of OFRAC was higher than that of 14YWT by ~35 MPa at 800ºC. At 900ºC, the UTS of OFRAC and 14YWT was similar at 900ºC and at 1000ºC, the UTS of 14YWT was higher than that of OFRAC by ~10 MPa. The ductility properties of OFRAC were greater than that of 14YWT with higher values of uniform elongation (UE) and total elongation (TE) at all tensile test temperatures. The creep properties of 14YWT and OFRAC were evaluated by the strain rate jump test method at 800ºC. The stress exponent (n) for creep was obtained from the SRJ test data by plotting the values of the log strain rate against the log stress, which is measured from the stress-strain curve generated during the SRJ test. The results showed the highest stress exponents of n = 19.8 and n = 35.0 were measured from the two SRJ tests on 14YWT. The stress exponent measured from one successful SRJ test on OFRAC was n = 13.3, which was lower than that of 14YWT. Nevertheless, these high values of stress exponent are consistent with ODS ferritic alloys such as 14YWT and OFRAC since they indicate dislocation-particle interactions are the dominant creep mechanism for specific ranges of temperature and stress. The results obtained from the tensile and SRJ creep tests conducted on axial specimens in this study indicate that 14YWT and OFRAC retain high strengths at temperatures up to 1,000ºC and good creep performance at 800ºC.

36 MATERIALS SCIENCE↗
DOE OSTI2022

Computational Fluid Dynamics Simulations to Predict Oxidation in Heat Recovery Steam Generator Tubes

Heat Recovery Steam Generators (HRSGs) are widely used across United States in combined cycle power plants to recover waste heat from the gas turbine (GT). HRSGs are used either to generate electricity or to produce process steam for industrial applications. The primary components of HRSG consists of a duct and a heat exchanger (HX). It is known across the power industry that the high temperature oxidation and ensuing exfoliation problem is a major cause for the damage of HX materials of HRSG. Alloys and/or coatings that can prevent or mitigate oxidation are very expensive, therefore they must be used or applied on the select regions of the HX tubes where the tendency of oxide formation is the highest. The main goal of this project is to identify such regions through Computational Fluid Dynamics (CFD) simulations. Therefore, in this work, we developed a CFD framework using commercial code StarCCM+ for the prediction of the fluid flow and heat transfer in a HRSG and associated oxidation inside the tubes of the HX. The developed CFD framework was verified and validated with experimental data before deployment. We also developed an innovative method to model the effect of the fins on the heat transfer and the pressure drop using a porous media model (PMM) approach to keep the mesh size within reasonable limits. After validation, we performed high-fidelity CFD simulations of a real-scale HRSG using the PMM, with High Performance Computing (HPC) resources of ORNL. From the simulation results, we acquired oxide thickness maps for all the tubes of the select HX sections of HRSG prone to oxidation. These oxide maps can inform regions of the HX tubes that requires oxide-resistant coatings, thereby guiding engineers for cost-efficient manufacturing of the HX that can combat oxidation in HRSGs.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Safety First: Stability and Dissipation of Line-tied Force-free Flux Tubes in Magnetized Coronae

Abstract Magnetized plasma columns and extended magnetic structures with both footpoints anchored to a surface layer are an important building block of astrophysical dissipation models. Current loops shining in X-rays during the growth of plasma instabilities are observed in the corona of the Sun and are expected to exist in highly magnetized neutron star magnetospheres and accretion disk coronae. For varying twist and system sizes, we investigate the stability of line-tied force-free flux tubes and the dissipation of twist energy during instabilities using linear analysis and time-dependent force-free electrodynamics simulations. Kink modes ( m = 1) and efficient magnetic energy dissipation develop for plasma safety factors q ≲ 1, where q is the inverse of the number of magnetic field line windings per column length. Higher-order fluting modes ( m > 1) can distort equilibrium flux tubes for q > 1 but induce significantly less dissipation. In our analysis, the characteristic pitch μ ˜ 0 of flux-tube field lines determines the growth rate ( ∝ μ ˜ 0 3 ) and minimum wavelength of the kink instability ( ∝ μ ˜ 0 − 1 ). We use these scalings to determine a minimum flux tube length for the growth of the kink instability for any given μ ˜ 0 . By drawing analogies to idealized magnetar magnetospheres with varying regimes of boundary shearing rates, we discuss the expected impact of the pitch-dependent growth rates for magnetospheric dissipation in magnetar conditions.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2020

Steam generator with inclined tube sheet

A steam generation system may include a plurality of heat transfer tubes configured to circulate a secondary coolant of the steam generation system. The steam generation system may be thermally coupled to a reactor vessel, and the reactor vessel may be configured to house a primary coolant. Heat generated from within the reactor vessel may be transferred from the primary coolant to the secondary coolant. The steam generation system may further include an inclined tube sheet fluidly coupled to the plurality of heat transfer tubes. The inclined tube sheet may be attached to a wall of the reactor vessel in a non-horizontal orientation.

42 ENGINEERING↗
DOE OSTI2021

Design Optimization of A-Type Heat Exchangers based on High Performance, Non-Round Tubes

Air-to-refrigerant heat exchangers (HXs) have been the topic of considerable research as they are the fundamental heat transfer components of HVAC&R systems. For residential and commercial applications, indoor heat exchangers are often in A-type configurations to reduce air-conditioner system footprint while still delivering the required cooling or heating. Classical HX design practices typically assume a uniform frontal air velocity profile to facilitate the use of conventional tube-fin airside heat transfer and pressure drop correlations for performance prediction. However, it is well-reported throughout the literature that A-type HXs experience significant airflow maldistribution which can severely degrade HX performance. Additionally, recent advancements in simulation software such as Computational Fluid Dynamics (CFD), Finite Element Analysis (FEA) and optimization algorithms have led researchers to consider primary heat transfer surface optimization to achieve highly compact HXs which do not require fins. In this paper, an A-type HX which utilizes shape-optimized non-round tubes is optimized for minimum duct size and airside pressure drop. This is achieved through coupling of an experimentally validated finite volume HX model with automated 2D CFD simulations of airflow through the HX for airside thermal-hydraulic performance evaluation. Preliminary results show that the optimal designs deliver similar capacity while achieving 20% reductions in airside pressure drop and duct cross-section area. Additionally, the optimal design apex angles in this study were similar to those from previous A-Type HX optimization studies for conventional tube-fin HX geometries, suggesting that the apex angle for optimal A-Type configuration performance may be independent of tube geometry.

42 ENGINEERING↗
DOE OSTI2021

Heat Transfer and Pressure Drop Characteristics of Water Flow Boiling in Internally Enhanced Tubes

Flow boiling is a critical process for many thermal conversion processes such as HVAC&R, water heating, power generation and desalination applications. The major goal of this paper is to enhance the in-tube heat transfer for flow boiling of water and further improve the efficiency of the boiler. This paper presents an experimental investigation of the heat transfer and pressure drop characteristics for water under forced convection and boiling conditions inside both smooth and enhanced tubes. The results in the smooth copper tube are compared with several correlations and used as a baseline. The two-phase heat transfer and pressure drop performance of the water flow boiling in the internally enhanced tube is investigated, and the influence of internal surface pattern on the thermal characteristics is discussed. The relations of the heat transfer coefficient with mass flux, heat flux and vapor quality are analyzed according to the results.

Yang, Cheng-Min↗
DOE OSTI2022

Multi-zone shell and tube heat exchanger

A shell and tube heat exchanger has elongated shell having first and second opposing ends and an open interior. A core divides the open interior of the shell into first and second enclosed portions. The shell has first and second tube fluid openings at opposing ends. End plates divide the first and second enclosed portions into manifold portions and enclosed shell chamber portions. Tubes extend from the end plates, through the enclosed shell chambers to the core. Shell fluid openings are at sides of the elongated shell, a first fluid opening communicating with the first shell chamber, and a second fluid opening communicating with the second shell chamber. The shell has a long axis, and the end plates are angled relative to the long axis. The tubes are polygonal with rounded corners and straight sides. The heat exchanger can be used for both evaporation and condensation processes.

Sabau, Adrian S.↗
DOE OSTI2021

Creating Hydride Rim Structures in Zircaloy 4 Cladding Tubes to Mimic High Burnup

During their long service in commercial light water reactors, zirconium alloy cladding tubes are subject to oxidation and subsequent hydrogen pickup which can degrade the materials mechanical properties [1]. These degradations can lead to premature cladding ruptures during reactor power transients [2] as well as negatively impact the claddings post quench ductility following high temperature steam oxidation in thermal hydraulic transients [3]. Hydrogen has low solid solubility in zirconium and usually precipitates as brittle zirconium hydride platelets in the cladding metal matrix. Due to temperature driven diffusion (Soret effect) and the grain texture of stress relieved zirconium metal tubes, these hydrides precipitate with a circumferential orientation near the outer surface of the cladding tubes forming a hydride rim which can serve as a site for crack initiation during circumferential ‘hoop’ loading of the cladding [4rim formation][5]. In order to better understand the effect of hydride rims on the fracture behavior of stress relieved zirconium alloy cladding tubes a procedure to produce these rim-like structures is being developed at Idaho National Laboratory (INL).

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Monocoque shell and tube heat exchanger

A heat exchanger with a monocoque structure transfers heat between a first fluid and a second fluid. The heat exchanger in has a plurality of tubes through which the first fluid may flow in a direction, each of the plurality of tubes has a first mouth end, an N opposing second mouth end and a waist region between the first mouth end and the second mouth end. The heat exchanger also has one or more interconnected fluid channels through which the second fluid may flow, the one or more fluid channels lay generally in a plane, the plurality of tubes and the one or more fluid channels interleave such that heat may be transferred between the plurality of tubes and the one or more fluid channels, and the direction of flow of the first fluid is generally perpendicular to the plane of the one or more fluid channels.

Keolian, Robert M.↗