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6 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2013

A study of grout flow pattern analysis

A new disposal unit, designated as Salt Disposal Unit no. 6 (SDU6), is being designed for support of site accelerated closure goals and salt nuclear waste projections identified in the new Liquid Waste System plan. The unit is cylindrical disposal vault of 380 ft diameter and 43 ft in height, and it has about 30 million gallons of capacity. Primary objective was to develop the computational model and to perform the evaluations for the flow patterns of grout material in SDU6 as function of elevation of grout discharge port, and slurry rheology. A Bingham plastic model was basically used to represent the grout flow behavior. A two-phase modeling approach was taken to achieve the objective. This approach assumes that the air-grout interface determines the shape of the accumulation mound. The results of this study were used to develop the design guidelines for the discharge ports of the Saltstone feed materials in the SDU6 facility. The focusing areas of the modeling study are to estimate the domain size of the grout materials radially spread on the facility floor under the baseline modeling conditions, to perform the sensitivity analysis with respect to the baseline design and operating conditions such as elevation of discharge port, discharge pipe diameter, and grout properties, and to determine the changes in grout density as it is related to grout drop height. An axi-symmetric two-phase modeling method was used for computational efficiency. Based on the nominal design and operating conditions, a transient computational approach was taken to compute flow fields mainly driven by pumping inertia and natural gravity. Detailed solution methodology and analysis results are discussed here.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2012

Saltstone SDU6 Modeling Study

A new disposal unit, designated as Saltstone Disposal Unit 6 (SDU6), is being designed for support of site accelerated closure goals and salt waste projections identified in the new Liquid Waste System Plan. The unit is a cylindrical disposal cell of 375 ft in diameter and 43 ft in height, and it has a minimum 30 million gallons of capacity. SRNL was requested to evaluate the impact of an increased grout placement height on the flow patterns radially spread on the floor and to determine whether grout quality is impacted by the height. The primary goals of the work are to develop the baseline Computational Fluid Dynamics (CFD) model and to perform the evaluations for the flow patterns of grout material in SDU6 as a function of elevation of grout discharge port and grout rheology. Two transient grout models have been developed by taking a three-dimensional multiphase CFD approach to estimate the domain size of the grout materials radially spread on the facility floor and to perform the sensitivity analysis with respect to the baseline design and operating conditions such as elevation height of the discharge port and fresh grout properties. For the CFD modeling calculations, air-grout Volume of Fluid (VOF) method combined with Bingham plastic and time-dependent grout models were used for examining the impact of fluid spread performance for the initial baseline configurations and to evaluate the impact of grout pouring height on grout quality. The grout quality was estimated in terms of the air volume fraction for the grout layer formed on the SDU6 floor, resulting in the change of grout density. The study results should be considered as preliminary scoping analyses since benchmarking analysis is not included in this task scope. Transient analyses with the Bingham plastic model were performed with the FLUENT TM code on the high performance parallel computing platform in SRNL. The analysis coupled with a transient grout aging model was performed by using ANSYS-CFX code in the parallel computing platform in Mercer University. Recommended operational guidance was developed assuming that local shear rates and flow patterns related to radial spread along the SDU floor can be used as a measure of grout performance and spatial dispersion affected by the grout height and viscosity. The main conclusions drawn from the grout modeling and calculations are as follows: • The 5 ft height baseline results show that when the 150 gpm grout flow with a 5 Pa yield stress and a 60 cp viscosity is poured down through a 3 inch discharge port, the grout is spread radially up to about 64 ft distance from the pouring center after 2 hours’ pouring time. The air volume fraction of the grout layer is about 29% at 5 minutes’ transient time, and it is reduced by about 9% in 2 hours’ pouring time, resulting in the grout density consisting of about 80% grout and 20% air volume fractions. • The sensitivity results show that when the discharge port is located at a higher position, a larger amount of air is trapped inside the layer formed below the discharge port at the early transient time of less than 30 minutes because of the higher impinging momentum of the grout flow on the floor, resulting in the formation of less smooth layer. • The results clearly indicate that the radial spread for the 43 ft discharge port is about 10% faster than that of the 5 ft discharge port for the early transient period of 5 minutes. However, for the pouring time longer than half an hour, the discharge port height does not affect the radial distance spread on the disposal floor. • When grout quality is related to grout volume fraction, the grout volume fraction for the 43 ft discharge port has lower volume fraction than the 5 ft discharge port for the transient period of the first 5 minutes. However, for the pouring time longer than half an hour, the discharge port height does not affect the grout volume fraction for the layer accumulated on the disposal floor. • A modified Bingham plastic model coupled with time-dependent viscosity behavior was developed for conducting the initial scoping calculations to assess the impact of fluid residence time on radial spreading and basic flow patterns. • The results for the transient viscosity model show that when grout material becomes more viscous, the thickness of the grout layer accumulated on the floor becomes higher, but the radial distance spread on the horizontal floor becomes smaller. The early transient results for the grout density with about 32% air volume fractions are in reasonable agreement with those of the idealized Bingham plastic model. • It is recommended that the current models developed here be benchmarked against the experimental results for critical applications of the modeling results.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2012

Modeling analysis for grout hopper waste tank

The Saltstone facility at Savannah River Site (SRS) has a grout hopper tank to provide agitator stirring of the Saltstone feed materials. The tank has about 300 gallon capacity to provide a larger working volume for the grout nuclear waste slurry to be held in case of a process upset, and it is equipped with a mechanical agitator, which is intended to keep the grout in motion and agitated so that it won't start to set up. The primary objective of the work was to evaluate the flow performance for mechanical agitators to keep an adequate stirring of the feed materials and to estimate an agitator speed which provides acceptable flow performance with a 45 deg. pitched four-blade agitator. In addition, the power consumption required for the agitator operation was estimated. The modeling calculations were performed by taking two steps of the Computational Fluid Dynamics (CFD) modeling approach. A series of sensitivity calculations for different designs of agitators and operating conditions have been performed to investigate the impact of key parameters on the grout hydraulic performance in a 300-gallon hopper tank. Recommended operational guidance was developed by using the basic concept that local shear rates and flow patterns can be used as a measure of hydraulic performance and spatial stirring. Flow patterns and fluid residence time were estimated by a Lagrangian integration technique along the flow paths from the material feed inlet. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

Hydropower Geotechnical Foundations: Current Practice and Innovation Opportunities for Low-Head Applications

Hydropower is a renewable energy resource that produces electricity from flowing water under pressure. Engineered hydropower structures, such as dams, are used to create a hydraulic head, enabling a turbinegenerator unit to convert pressurized flow into electricity. While hydropower has been a source of renewable energy since antiquity, new development in the United States has slowed in recent decades. Based on recent resource assessments, the largest opportunity to expand hydropower in the United States is from new stream-reach development (i.e., new hydropower development along stream-reaches that do not currently have hydroelectric facilities or other forms of infrastructure, such as dams). Roughly 75% of identified new stream-reach development potential is from low-head sites (less than 30 ft of head), which typically suffer from smaller power densities and higher normalized costs, given economies of scale. Hydropower developers and other stakeholders are thus interested in strategies to reduce initial capital costs while practicing sustainable development to maximize environmental compatibility with minimal disruption to natural aquatic life, sediment, and water flows. Historically, civil works have represented a significant cost driver for new hydropower development, with the foundation system representing a major cost component and source of uncertainty. The foundation system is the collection of engineered structural features (e.g. cutoff trenches, walls, grouting, anchors) constructed at or below the preconstruction ground surface that interfaces between the overlying structures (superstructures) and the bed material below (subsurface). Development of a hydropower foundation system must consider the various characteristics of the surrounding stream environment and subsurface while adhering to the engineering requirements of the superstructure that it supports. The care of water, excavation, and other construction activities are important features of foundation design and construction. The design and construction cost of the foundation system is largely dependent on the site geology and riverbed composition and is influenced by the level of geotechnical assessment required and conducted. Thus, a hydropower facility’s geotechnical foundation is often highly site-specific, with proper site selection and assessment being important to project success. The foundation system is designed to provide structural stability (of the foundation and dam), limit seepage, ensure public safety, and maintain functionality for the project life, during both construction and facility operations. Inadequate foundation or dam design can result in dam failure and the uncontrolled release of significant volumes of water, which could cause a high number of casualties and extensive property damage downstream of the failure. According to the Association of State Dam Safety Officials, approximately 30% of all historical dam failures in the United States are attributed to foundation or abutment defects, and another 20% are attributed to piping or seepage through the embankment, foundation, or abutment. To ameliorate these safety considerations, foundations often require massive amounts of construction material (e.g., grout, concrete, engineered dam fill) and long construction times. Foundation design also requires significant analysis prior to construction because the initial in-stream and abutment subsurface conditions are site-specific, and sufficient data for them often are lacking. Current practice requires on-site assessment, using expensive drilling and invasive and non-invasive investigation methods, to determine the expected cost of foundation material and treatment. Additionally, foundation construction often requires site dewatering (and other care of water activities), which involves constructing temporary diversion structures upstream and often downstream, called cofferdams, and water diversion systems that route water around the construction site. Cofferdams and water diversion systems can drastically increase construction costs and contribute to environmental disruption, including modification of flow patterns and benthic habitats. Given the technical, economic, and environmental challenges associated with hydropower foundations, opportunities exist to improve the current state of practice and to develop new and innovative solutions to Hydropower is a renewable energy resource that produces electricity from flowing water under pressure. Engineered hydropower structures, such as dams, are used to create a hydraulic head, enabling a turbinegenerator unit to convert pressurized flow into electricity. While hydropower has been a source of renewable energy since antiquity, new development in the United States has slowed in recent decades. Based on recent resource assessments, the largest opportunity to expand hydropower in the United States is from new stream-reach development (i.e., new hydropower development along stream-reaches that do not currently have hydroelectric facilities or other forms of infrastructure, such as dams). Roughly 75% of identified new stream-reach development potential is from low-head sites (less than 30 ft of head), which typically suffer from smaller power densities and higher normalized costs, given economies of scale. Hydropower developers and other stakeholders are thus interested in strategies to reduce initial capital costs while practicing sustainable development to maximize environmental compatibility with minimal disruption to natural aquatic life, sediment, and water flows. Historically, civil works have represented a significant cost driver for new hydropower development, with the foundation system representing a major cost component and source of uncertainty. The foundation system is the collection of engineered structural features (e.g. cutoff trenches, walls, grouting, anchors) constructed at or below the preconstruction ground surface that interfaces between the overlying structures (superstructures) and the bed material below (subsurface). Development of a hydropower foundation system must consider the various characteristics of the surrounding stream environment and subsurface while adhering to the engineering requirements of the superstructure that it supports. The care of water, excavation, and other construction activities are important features of foundation design and construction. The design and construction cost of the foundation system is largely dependent on the site geology and riverbed composition and is influenced by the level of geotechnical assessment required and conducted. Thus, a hydropower facility’s geotechnical foundation is often highly site-specific, with proper site selection and assessment being important to project success. The foundation system is designed to provide structural stability (of the foundation and dam), limit seepage, ensure public safety, and maintain functionality for the project life, during both construction and facility operations. Inadequate foundation or dam design can result in dam failure and the uncontrolled release of significant volumes of water, which could cause a high number of casualties and extensive property damage downstream of the failure. According to the Association of State Dam Safety Officials, approximately 30% of all historical dam failures in the United States are attributed to foundation or abutment defects, and another 20% are attributed to piping or seepage through the embankment, foundation, or abutment. To ameliorate these safety considerations, foundations often require massive amounts of construction material (e.g., grout, concrete, engineered dam fill) and long construction times. Foundation design also requires significant analysis prior to construction because the initial in-stream and abutment subsurface conditions are site-specific, and sufficient data for them often are lacking. Current practice requires on-site assessment, using expensive drilling and invasive and non-invasive investigation methods, to determine the expected cost of foundation material and treatment. Additionally, foundation construction often requires site dewatering (and other care of water activities), which involves constructing temporary diversion structures upstream and often downstream, called cofferdams, and water diversion systems that route water around the construction site. Cofferdams and water diversion systems can drastically increase construction costs and contribute to environmental disruption, including modification of flow patterns and benthic habitats. Given the technical, economic, and environmental challenges associated with hydropower foundations, opportunities exist to improve the current state of practice and to develop new and innovative solutions to challenges frequently encountered with traditional approaches. With this understanding, it is critically important to understand and document the current state of practice for hydropower geotechnical foundations, identify key challenges, and define opportunities for innovative solutions. To this end, this report documents the current state of practice across the three main phases of geotechnical foundation development: (1) geotechnical site assessment, (2) design, and (3) construction for hydropower systems. It also describes the major challenges with conventional approaches and identifies opportunities for innovation to reduce hydropower foundations costs, timelines, and risks. Key takeaways from this report include the following: Approximately 80% of available low-head sites are expected to have foundations on soil beds rather than rock beds, suggesting that rockfill and earthfill dams may be the most cost-effective conventional dam type for new projects.; Geotechnical and geologic investigation activities are time-consuming and expensive but are essential to define the parameters and criteria needed for foundation design.; Certain riverbed soil and bedrock types present significant technical challenges or require expensive foundation construction, which can prove financially prohibitive for low-head project development.; Modular hydropower design and prefabricated modular foundations represent a promising but unproven paradigm for new hydropower development. Design and construction approaches using optimized and highly repeatable, reliable components would benefit project cost, time, and risk but require additional research and development.; Temporary construction features for foundations, including cofferdams, water diversion, and water control systems, can prove costly and have inherent construction risk.; For economically viable development, hydropower geotechnical foundations should be limited to 4 to 15% of the project’s total initial capital costs. Many proposed projects have experienced cost overruns attributable to foundation difficulties or surprises during construction. These overruns may have been due to inadequate investigations, lack of adequate engineering effort to tailor the structures to site geology and topography, and/or contractual terms, among other considerations.; Challenges for hydropower foundations and opportunities for innovative technology solutions are identified in the following areas (consistent with the three main phases of foundation development): Geotechnical site assessment, Foundation design and materials, Construction methods and technology. Ultimately, this report aims to provide information about geotechnical foundations for low-head hydropower and to motivate transformative technologies to support hydropower growth.

13 HYDRO ENERGY↗
DOE OSTI2024

The EGS Collab project: Outcomes and lessons learned from hydraulic fracture stimulations in crystalline rock at 1.25 and 1.5 km depth

With the goal of better understanding stimulation in crystalline rock for improving enhanced geothermal systems (EGS), the EGS Collab Project performed a series of stimulations and flow tests at 1.25 and 1.5 km depths. The tests were performed in two well-instrumented testbeds in the Sanford Underground Research Facility in Lead, South Dakota, United States. The testbed for Experiment 1 at 1.5 km depth contained two open wells for injection and production and six instrumented monitoring wells surrounding the targeted stimulation zone. Four multi-step stimulation tests targeting hydraulic fracturing and nearly year-long ambient temperature and chilled water flow tests were performed in Experiment 1. The testbed for Experiments 2 and 3 was at 1.25 km depth and contained five open wells in an outwardly fanning five-spot pattern and two fans of well-instrumented monitoring wells surrounding the targeted stimulation zone. Experiment 2 targeted shear stimulation, and Experiment 3 targeted low-flow, high-flow, and oscillating pressure stimulation strategies. Hydraulic fracturing was successful in Experiments 1 and 3 in generating a connected system wherein injected water could be collected. However, the resulting flow was distributed dynamically, and not entirely collected at the anticipated production well. Thermal breakthrough was not observed in the production well, but that could have been masked by the Joule-Thomson effect. Shear stimulation in Experiment 2 did not occur - despite attempting to pressurize the fractures most likely to shear - because of the inability to inject water into a mostly-healed fracture, and the low shear-to-normal stress ratio. The EGS Collab experiments are described to provide a background for lessons learned on topics including induced seismicity, the correlation between seismicity and permeability, distributed and dynamic flow systems, thermoelastic and pressure effects, shear stimulation, local geology, thermal breakthrough, monitoring stimulation, grouting boreholes, modeling, and system management.

15 - GEOTHERMAL ENERGY↗
DOE OSTI2018

Experimental Technetium Release from Simulated Salt-stone Cementitious Waste Form - 18419

Experiments are being conducted to evaluate the early release of technetium (Tc) from fresh salt-stone waste forms using dynamic flow-through tests. Salt-stone is a chemically reducing, grout-based waste form used by the U.S. Department of Energy (DOE) to dispose of low-activity salt solutions arising from high-level radioactive waste tank closure activities at the Savannah River Site (SRS). A key safety function of salt-stone is maintaining a low-flow, chemically reducing environment that will attenuate the release of redox-sensitive radioelements such as Tc. Salt-stone also provides a physical barrier due to its low intrinsic permeability, which limits both water and oxygen ingress. These release experiments, conducted to support the U.S. Nuclear Regulatory Commission's monitoring role during tank closure, are designed to provide independent information on how well salt-stone will perform its safety function. The dynamic leach tests were conducted in a Hassler-type core-holder permeameter system that allows an accelerated flow rate of simulated SRS groundwater through an intact cylinder of salt-stone spiked with Tc-99 at a concentration of approximately 2,100 Bq/g (3 ppm). The first salt-stone specimen to be tested (Specimen 2) was prepared with Grade 100 ground granulated blast-furnace slag and aged for 119 days in a temperature-controlled, low-oxygen, high-humidity environment. Before test completion, 9.5 pore volumes (PV) of simulated SRS groundwater were passed through the salt-stone cylinder. After a few PV, apparent saturated hydraulic conductivity (K{sub sat}) values calculated from flow data reached a steady-state value of approximately 1.0 x 10{sup -9} cm/s, which is within the range of previously reported data. Tc-99 concentrations in leachate peaked early during the leach test at 2.0 x 10{sup -7} M and then declined to approximately 4 x 10{sup -8} M after 9.5 PV. The leachate Tc-99 concentration after elution of 9.5 PV is broadly consistent with a Tc solution concentration controlled by the solubility of reduced Tc solids. The range of Tc-99 concentrations is similar to the range reported for a column test that was sponsored by DOE, but the time pattern of release differs. The second salt-stone specimen tested (Specimen 3) was aged for 372 days and it further differed from the first specimen in that its Grade 100 slag component had been finely ground using a mortar and pestle in an attempt to make it more reactive. This second test yielded Tc release behavior broadly similar to that observed during the first test, except that the early Tc peak (at 1.2 x 10{sup -6} M) was six times higher and the concentration after 6.7 PV (8.8 x 10{sup -8} M) was approximately two times higher than in the first test. In addition, the steady-state K{sub sat} was an order of magnitude lower than that of the first specimen. During the second test, the injection pump was intentionally turned off for a period of 11 days (i.e., approximate residence time for 1 PV) and a Tc spike was observed when pumping resumed, suggesting that longer residence times may promote higher Tc effluent concentrations. During a second intentional shut-down of the pump for 25 days (approximate residence time for 2 PV), another Tc spike was observed. An unplanned excursion to higher confining pressure physically affected the specimen, temporarily lowering the apparent K{sub sat} followed by a subsequent increase in both K{sub sat} and Tc effluent concentration. One hypothesis is that the transient spike in confining pressure and resulting salt-stone compression and later decompression may have induced Tc release from otherwise inactive pores. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗