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At least 19 records

Non-Nuclear Testing of Compact Reactor Technologies at NASA MSFC

Safe, reliable, compact, autonomous, long-life fission systems have numerous potential applications, both terrestrially and in space. Technologies and facilities developed in support of these systems could be useful to a variety of concepts. At moderate power levels, fission systems can be designed to operate for decades without the need for refueling. In addition, fast neutron damage to cladding and structural materials can be maintained at an acceptable level. Nuclear design codes have advanced to the stage where high confidence in the behavior and performance of a system can be achieved prior to initial testing. To help ensure reactor affordability, an optimal strategy must be devised for development and qualification. That strategy typically involves a combination of non-nuclear and nuclear testing. Non-nuclear testing is particularly useful for concepts in which nuclear operating characteristics are well understood and nuclear effects such as burnup and radiation damage are not likely to be significant. To be mass efficient, a SFPS must operate at higher coolant temperatures and use different types of power conversion than typical terrestrial reactors. The primary reason is the difficulty in rejecting excess heat to space. Although many options exist, NASA s current reference SFPS uses a fast spectrum, pumped-NaK cooled reactor coupled to a Stirling power conversion subsystem. The reference system uses technology with significant terrestrial heritage while still providing excellent performance. In addition, technologies from the SFPS system could be applicable to compact terrestrial systems. Recent non-nuclear testing at NASA s Early Flight Fission Test Facility (EFF-TF) has helped assess the viability of the reference SFPS and evaluate methods for system integration. In July, 2011 an Annular Linear Induction Pump (ALIP) provided by Idaho National Laboratory was tested at the EFF-TF to assess performance and verify suitability for use in a10 kWe technology demonstration unit (TDU). In November, 2011 testing of a 37-pin core simulator (designed in conjunction with Los Alamos National Laboratory) for use with the TDU will occur. Previous testing at the EFFTF has included the thermal and mechanical coupling of a pumped NaK loop to Stirling engines (provided by GRC). Testing related to heat pipe cooled systems, gas cooled systems, heat exchangers, and other technologies has also been performed. Integrated TDU testing will begin at GRC in 2013. Thermal simulators developed at the EFF-TF are capable of operating over the temperature and power range typically of interest to compact reactors. Small and large diameter simulators have been developed, and simulators (coupled with the facility) are able to closely match the axial and radial power profile of all potential systems of interest. A photograph of the TDU core simulator during assembly is provided in Figure 2.

Houts, Michael G.

Phase 1 Space Fission Propulsion System Design Considerations

Fission technology can enable rapid, affordable access to any point in the solar system. If fission propulsion systems are to be developed to their full potential; however, near-term customers must be identified and initial fission systems successfully developed, launched, and operated. Studies conducted in fiscal year 2001 (IISTP, 2001) show that fission electric propulsion (FEP) systems operating at 80 kWe or above could enhance or enable numerous robotic outer solar system missions of interest. At these power levels it is possible to develop safe, affordable systems that meet mission performance requirements. In selecting the system design to pursue, seven evaluation criteria were identified: safety, reliability, testability, specific mass, cost, schedule, and programmatic risk. A top-level comparison of three potential concepts was performed: an SP-100 based pumped liquid lithium system, a direct gas cooled system, and a heatpipe cooled system. For power levels up to at least 500 kWt (enabling electric power levels of 125-175 kWe, given 25-35% power conversion efficiency) the heatpipe system has advantages related to several criteria and is competitive with respect to all. Hardware-based research and development has further increased confidence in the heatpipe approach. Successful development and utilization of a "Phase 1" fission electric propulsion system will enable advanced Phase 2 and Phase 3 systems capable of providing rapid, affordable access to any point in the solar system.

Houts, Mike

Direct-Drive Gas-Cooled Reactor Power System: Concept and Preliminary Testing

This paper describes the concept and preliminary component testing of a gas-cooled, UN-fueled, pin-type reactor which uses He/Xe gas that goes directly into a recuperated Brayton system to produce electricity for nuclear electric propulsion. This Direct-Drive Gas-Cooled Reactor (DDG) is designed to be subcritical under water or wet- sand immersion in case of a launch accident. Because the gas-cooled reactor can directly drive the Brayton turbomachinery, it is possible to configure the system such that there are no external surfaces or pressure boundaries that are refractory metal, even though the gas delivered to the turbine is 1144 K. The He/Xe gas mixture is a good heat transport medium when flowing, and a good insulator when stagnant. Judicious use of stagnant cavities as insulating regions allows transport of the 1144-K gas while keeping all external surfaces below 900 K. At this temperature super-alloys (Hastelloy or Inconel) can be used instead of refractory metals. Super-alloys reduce the technology risk because they are easier to fabricate than refractory metals, we have a much more extensive knowledge base on their characteristics, and, because they have a greater resistance to oxidation, system testing is eased. The system is also relatively simple in its design: no additional coolant pumps, heat exchanger, or freeze-thaw systems are required. Key to success of this concept is a good knowledge of the heat transfer between the fuel pins and the gas, as well as the pressure drop through the system. This paper describes preliminary testing to obtain this key information, as well as experience in demonstrating electrically heated testing of simulated reactor components.

Wright, S. A.

The feasibility of low-G grey solidification of nodular iron in the F-104 experimental furnace package

The rationale for low-g experiments with cast iron and the need for solidification in the grey form during these experiments are reviewed. The factors which determine whether an iron melt will solidify grey or white are discussed. Cooling rate versus microstructure was studied for a nodular iron candidate material for F-104 low-g solidification. The study determined that low-g grey solidification, using the present F-104 furnace system, of the nodular iron composition studied is not feasible. Specimen microstructure strongly suggested that the F-104 furnace's gas cooling system was causing excessive localized chill resulting in the nucleation of the unwanted iron carbide phase. A change is suggested, in the quench system design, that could possibly overcome this problem.

Curreri, P. A.

Cooled Gas Turbine and Combined Cycle Analysis for NH 3 -CH 4 Fuel Mixes (Up to 100% NH 3 )

In this study, a cooled gas turbine (GT) analysis was conducted for varying levels of ammonia (NH 3 ) blends with methane. The ultimate goal is to have a gas turbine design that can be used for all the fuel blends (including 100% NH 3 ) without any changes to the system. The technological developments in the cooling system, gas turbine design, and materials that will be required for NH 3 combustion were identified and analyzed in this study to develop an advanced gas turbine design for NH 3 fuels. The study includes a combined cycle performance analysis with the NH 3 fuel blends using the advanced gas turbine design developed in this study. A techno-economic analysis was conducted for analyzing the impact of the NH 3 fuels on the levelized cost of electricity and cost sensitivities to fuel price and capacity factor.

20 FOSSIL-FUELED POWER PLANTS

Oil cooling system for a gas turbine engine

A gas turbine engine fuel delivery and control system is provided with means to recirculate all fuel in excess fuel control requirements back to the aircraft fuel tank. This increases the fuel pump heat sink and decreases the pump temperature rise without the addition of valving other than normally employed. A fuel/oil heat exchanger and associated circuitry is provided to maintain the hot engine oil in heat exchange relationship with the cool engine fuel. Where anti-icing of the fuel filter is required, means are provided to maintain the fuel temperature entering the filter at or above a minimum level to prevent freezing thereof. In one embodiment, a divider valve is provided to take all excess fuel from either upstream or downstream of the fuel filter and route it back to the tanks, the ratio of upstream to downstream extraction being a function of fuel pump discharge pressure.

Coffinberry, G. A.

Oil cooling system for a gas turbine engine

A gas turbine engine fuel delivery and control system is provided with means to recirculate all fuel in excess of fuel control requirements back to aircraft fuel tank, thereby increasing the fuel pump heat sink and decreasing the pump temperature rise without the addition of valving other than that normally employed. A fuel/oil heat exchanger and associated circuitry is provided to maintain the hot engine oil in heat exchange relationship with the cool engine fuel. Where anti-icing of the fuel filter is required, means are provided to maintain the fuel temperature entering the filter at or above a minimum level to prevent freezing thereof. Fluid circuitry is provided to route hot engine oil through a plurality of heat exchangers disposed within the system to provide for selective cooling of the oil.

Coffinberry, G. A.

Gas cooled fuel cell systems technology development

The first phase of a planned multiphase program to develop a Phosphoric is addressed. This report describes the efforts performed that culminated in the: (1) Establishment of the preliminary design requirements and system conceptual design for the nominally rated 375 kW PAFC module and is interfacing power plant systems; (2) Establishment of PAFC component and stack performance, endurance, and design parameter data needed for design verification for power plant application; (3) Improvement of the existing PAFC materials data base and establishment of materials specifications and process procedes for the cell components; and (4) Testing of 122 subscale cell atmospheric test for 110,000 cumulative test hours, 12 subscale cell pressurized tests for 15,000 cumulative test hours, and 12 pressurized stack test for 10,000 cumulative test hours.

Feret, J. M.

Gas cooled fuel cell systems technology development

The work performed during the Second Logical Unit of Work of a multi-year program designed to develop a phosphoric acid fuel cell (PAFC) for electric utility power plant application is discussed. The Second Logical Unit of Work, which covers the period May 14, 1983 through May 13, 1984, was funded by the U.S. Department of Energy, Office of Fossil Energy, Morgantown Energy Technology Center, and managed by the NASA Lewis Research Center.

Feret, J. M.

Effect of thermal barrier coatings on the performance of steam and water-cooled gas turbine/steam turbine combined cycle system

An analytical study was made of the performance of air, steam, and water-cooled gas-turbine/steam turbine combined-cycle systems with and without thermal-barrier coatings. For steam cooling, thermal barrier coatings permit an increase in the turbine inlet temperature from 1205 C (2200 F), resulting in an efficiency improvement of 1.9 percentage points. The maximum specific power improvement with thermal barriers is 32.4 percent, when the turbine inlet temperature is increased from 1425 C (2600 F) to 1675 C (3050 F) and the airfoil temperature is kept the same. For water cooling, the maximum efficiency improvement is 2.2 percentage points at a turbine inlet temperature of 1683 C (3062 F) and the maximum specific power improvement is 36.6 percent by increasing the turbine inlet temperature from 1425 C (2600 F) to 1730 C (3150 F) and keeping the airfoil temperatures the same. These improvements are greater than that obtained with combined cycles using air cooling at a turbine inlet temperature of 1205 C (2200 F). The large temperature differences across the thermal barriers at these high temperatures, however, indicate that thermal stresses may present obstacles to the use of coatings at high turbine inlet temperatures.

Nainiger, J. J.

High Fidelity Simulations of Air-Cooled Reactor Cavity Cooling System

High Temperature Gas Reactor (HTGR) designs incorporate passive safety systems (e.g., the Reactor Cavity Cooling System [RCCS]) that utilize natural principles to manage heat dissipation from the reactor pressure vessel (RPV) during accidents or routine shutdowns. The industry community is experiencing a pressing need for advanced simulation tools that can accurately assess the performance of these types of systems. In the literature, a knowledge gap exists concerning high-fidelity data for the RCCS, and this gap is one of the areas of focus of the present study. This research focuses on a specific RCCS designed for General Atomics' Modular High-Temperature Gas Reactor (GA-MHTGR). Experimental studies on a scaled version (can be seen in Figure 1) of the air-cooled RCCS used in GA-MHTGR were conducted by the University of Wisconsin-Madison (UW-Madison). This work contributes to a broader initiative aimed at establishing a numerical benchmark based on the UW-Madison experiments.

22 GENERAL STUDIES OF NUCLEAR REACTORS

Multi-physics Modeling of Radiative Heat Transfer and Fluid Flow for the Reactor Cavity Cooling System

High-temperature gas-cooled reactors (HTGRs) are notable for their high thermal efficiency and potential for combined heat and power applications. These reactors are particularly appealing due to their advanced passive safety features. HTGRs utilize passive safety systems that function without requiring active components like pumps or compressors during emergencies. These reactor designs depend on a Reactor Cavity Cooling System (RCCS) to manage decay heat removal from the reactor pressure vessel (RPV) during accident conditions. The RCCS consists of vertical rectangular channels known as "risers" or riser ducts positioned around the RPV. These risers receive heat from the RPV through both convective and radiative heat transfer mechanisms. Understanding the interplay of multiple physical phenomena, such as fluid dynamics, heat transfer, and neutron interactions, is essential for the effective design and operation of nuclear reactors, particularly for systems like the RCCS. Multi-physics simulations provide a comprehensive approach to studying these interactions, offering detailed insights and enhancing accuracy. They are especially important in RCCS designs, where the interaction between radiative and convective heat transfer can significantly impact system performance. By leveraging multi-physics simulations, complex reactor behaviors can be modeled without compromising the fidelity of the underlying physical processes. This work aims to establish a robust methodology for coupling multiple physical processes in an air-cooled RCCS. By focusing on validating this multi-physics approach, the study involves designing test cases that simulate various conditions to verify the numerical models employed. The outcomes of this research will provide critical insights for accurately modeling and optimizing complex nuclear systems like the RCCS.

22 GENERAL STUDIES OF NUCLEAR REACTORS

Dynamic Response Testing in an Electrically Heated Reactor Test Facility

Non-nuclear testing can be a valuable tool in development of a space nuclear power or propulsion system. In a non-nuclear test bed, electric heaters are used to simulate the heat from nuclear fuel. Standard testing allows one to fully assess thermal, heat transfer, and stress related attributes of a given system, but fails to demonstrate the dynamic response that would be present in an integrated, fueled reactor system. The integration of thermal hydraulic hardware tests with simulated neutronic response provides a bridge between electrically heated testing and full nuclear testing. By implementing a neutronic response model to simulate the dynamic response that would be expected in a fueled reactor system, one can better understand system integration issues, characterize integrated system response times and response characteristics, and assess potential design improvements at a relatively small fiscal investment. Initial system dynamic response testing was demonstrated on the integrated SAFE-100a heat pipe cooled, electrically heated reactor and heat exchanger hardware, utilizing a one-group solution to the point kinetics equations to simulate the expected neutronic response of the system (Bragg-Sitton, 2005). The current paper applies the same testing methodology to a direct drive gas cooled reactor system, demonstrating the applicability of the testing methodology to any reactor type and demonstrating the variation in system response characteristics in different reactor concepts. In each testing application, core power transients were controlled by a point kinetics model with reactivity feedback based on core average temperature; the neutron generation time and the temperature feedback coefficient are provided as model inputs. Although both system designs utilize a fast spectrum reactor, the method of cooling the reactor differs significantly, leading to a variable system response that can be demonstrated and assessed in a non-nuclear test facility.

Bragg-Sitton, Shannon M.

Nuclear—thermal energy storage configurations for industrial combined heat and power supply—conceptual and thermodynamic study with high temperature gas-cooled reactor

Nuclear systems are promising candidates for delivering resilient heat and power for future energy security and independence. Traditionally, nuclear plants have been used for baseload electricity production and cogeneration of heat has seen relatively limited application utilizing typically only small portion of a reactor's thermal output. This paradigm may shift due to the increasing penetration of intermittent renewables and need for resource flexibility, various decarbonization efforts aimed at both electricity and heat demands, along with the perspective of small modular nuclear reactor applications, which can be sized based on local industrial needs. Here, this study provides a comprehensive guide for the nuclear and industrial sectors, emphasizing controllability in the combined heat and power configuration options for high temperature gas-cooled reactor and process steam supply. It investigates the integration of thermal energy storage to improve nuclear energy's responsiveness to varying industrial demands. The study emphasizes placing thermal energy storage between the nuclear primary loop and steam cycle to achieve greater efficiency and flexibility in power and heat output, surpassing traditional combined heat and power systems and avoiding efficiency losses seen in other thermal energy storage integration approaches.

combined heat and power (CHP)

Cyrogenic Life Support Technology Development Project

KSC has used cryogenic life support (liquid air based) technology successfully for many years to support spaceflight operations. This technology has many benefits unique to cryogenics when compared to traditional compressed gas systems: passive cooling, lighter, longer duration, and lower operating pressure. However, there are also several limiting factors that have prevented the technology from being commercialized. The National Institute of Occupational Safety and Health, Office of Mine Safety and Health Research (NIOSH-OMSHR) has partnered with NASA to develop a complete liquid air based life support solution for emergency mine escape and rescue. The project will develop and demonstrate various prototype devices and incorporate new technological innovations that have to date prevented commercialization.

compressed gas systems: passive cooling

Kinetic modeling of an IBr solar pumped laser

The possibility of using an IBr laser as a solar-energy converter is examined theoretically, and reasons for its choice are given. Broadband absorption results in dissociation with the formation of excited metastable Br atoms, some of which then lase to the ground state Br. The ground state is depopulated by three-body recombination and, more importantly, by exchange reactions which more than compensate for the high quenching in heteronuclear halogen systems. Kinetic modeling indicates lasing is possible in the pulsed mode and possibly in the steady state with a cooled gas flow system. Temperature effects are discussed. The efficiency of the laser approaches 1.2 percent at optical thicknesses large enough for complete absorption of the photons.

Harries, W. L.