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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 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Heat load measurements for the PIP-II pHB650 cryomodule

This study presents a brief overview of the 1st and 2nd phases and an in-depth analysis of the 3rd phase heat load testing performed on the pHB650 (prototype High Beta 650 MHz) cryomodule at PIP2IT (PIP-II Injector Test Facility), with a focus on both the results and the methodological advancements that have improved testing efficiency and accuracy. A key challenge identified in the testing campaign is the higher-than-expected heat loads observed in the first PIP-II (Proton Improvement Plan II) prototype cryomodules (pSSR1 and pHB650) tested at PIP2IT. Elevated heat loads are concerning given the fixed capacity of the PIP-II cryoplant that is currently being installed at Fermilab. However, understanding the sources of these elevated heat loads offers a critical opportunity to implement effective heat load mitigations on upcoming PIP-II cryomodules to stay within the available capacity of the PIP-II cryoplant. The study includes a summary of test results, descriptions of measurement procedures, and key observations on parameters directly and indirectly related to heat load measurements. Direct observations include measured heat loads and the effectiveness of JT heat exchanger under varying conditions, while indirect observation analyze factors such as the temperature distribution on the two-phase pipe and relief piping under varying conditions. Thermal acoustic oscillations (TAO) were identified during testing, which was mitigated by replacing the original G10 stem with a stainless steel stem equipped with wipers for the cryomodule cooldown valve. A major innovation during pHB650 Phase 3 testing was the development of an automated Python script to streamline data acquisition, analysis, and reporting of heat load results. This script automatically retrieved data from ACNET (Accelerator Control Network), performed heat load calculations, and generated detailed reports featuring plots and tables. This advancement significantly reduced manual labor and enhanced the thoroughness of data analysis compared to earlier campaigns. The heat load test reports were promptly uploaded to the electronic logbook shortly after each test, enabling rapid feedback and collaboration between the SRF and cryogenic teams. The heat load measurements included various components: HTTS (high-temperature thermal shield), LTTS (low-temperature thermal shield), 2K isothermal and non-isothermal heat loads. Results were recorded both within the cryomodule and between the bayonet can supply and return. Measurements were conducted under different operating conditions such as "standard", "linac", and "simulated dynamic". Additionally, HTTS and LTTS heat loads were calculated in real time, allowing for the tracking of thermal stability and identification of changes during testing, both in steady-state and transient conditions. The results of this testing campaign not only provide valuable insights into the performance of the pHB650 cryomodule but also highlight best practices and lessons learned that will inform future cryomodule testing at PIP2IT. These include adopting automated tools for data analysis, refining real-time measurement capabilities, and emphasizing detailed pre-test planning. The framework established in this campaign aims to set an improved standard for cryomodule testing and heat load reporting in future cryomodule test campaigns.

Porwisiak, D. [Fermilab; Wroclaw Tech. U.]↗
DOE OSTI2024

Radioisotope Power System Cask Trailer Chiller Low Heat Load Study

This report documents the study of the Radioisotope Thermoelectric Generator Transport System (RTGTS) chillers capability to transport a Radioisotope Power System (RPS) with low heat loads in the cask. Tests of the RTGTS chillers included setting the glycol/water (coolant) temperature to a control set point of 40° and 60°F while applying heat loads ranging from 2500 to 0 W heat load. The tests performed showed that the chiller systems could handle the entire range of heat loads. However, a noise/vibration started to occur when the set point was 60°F with low heat loads. Three recommended changes to the RTGTS chillers are recommended with varying implementation windows. The first is an operational change that can be implemented immediately. The RTGTS chillers should have a set point of 40°F when transporting an RPS less than 1500 W. The second is a short-term change (within the next two years) augmenting RPS heat by utilizing one RTGTS onboard heater (2500 W) while transporting an RPS with less than 1500 W which will also require a change to the Instrument and Data Acquisition System (IDAS) to allow monitoring and possible control of power to the onboard heaters. However, if the heater does fail during transport, no emergency actions or immediate repairs will be required due to the chillers’ ability to handle low heat loads. Running a 2500 W heater when transporting low heat loads aids in prolonging the life of the chillers. The remaining recommended long-term change is to replace the current chillers with a new portable or permanently installed chiller system in the next five to ten years. This time frame takes advantage of the proven reliability and durability of the current chillers while the new chillers are phased in and proven to the RPS program.

42 ENGINEERING↗
DOE OSTI2022

3D ion gyro-orbit heat load predictions for NSTX-U

Abstract High power tokamaks operate with divertor heat loads capable of destroying the plasma facing components (PFCs). High fidelity heat load predictions are necessary to ascertain the PFC state for design and during operation. Typical heat flux calculations are 2D, time invariant, and assume that power flows directly along the magnetic field lines (the optical approximation). These assumptions neglect the complex 3D geometries employed to protect the PFCs, the time varying nature of the plasma and PFC thermal state, and the helical trajectories of ions with finite Larmor radii (the gyro-orbit approximation). An integrated software framework, the heat flux engineering analysis toolkit (HEAT), was developed to generate time varying optical heat loads applied to real engineering computer aided design (CAD) (Looby et al 2022 Fusion Sci. Technol. 78 10–27). Recently, an ion-gyro orbit module has been added to HEAT. This module calculates the helical trajectories of ions as they gyrate about the magnetic field lines using kinetic theory macro-particles to accelerate the calculation. First, the new gyro-orbit module will be presented. Next, a comparison to existing research is performed. Finally, an analysis of the gyro-orbit heat loads for NSTX-U is presented for diverted discharges using the engineering CAD models utilized for PFC fabrication. Including these gyro-orbit effects can enhance the PFC performance by ‘smearing’ out the magnetic shadows associated with the castellated fish-scaled geometry. Simultaneously, the helical trajectories can degrade performance when they load narrow regions on edges and corners with high heat fluxes. Analysis of the trade-offs between these competing effects is included, and regions for further investigation are identified.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2026

Heat load measurements for the PIP-II pHB650 cryomodule

Phase-3 testing of the pHB650 cryomodule at the PIP-II Injector Test Facility was conducted to evaluate the effectiveness of heat load mitigations performed after earlier phases of testing and to continue pinpointing any sources of unexpectedly high heat loads.. The programme measured HTTS, LTTS, and 2 K isothermal/non-isothermal loads under "standard", "linac", and "simulated dynamic" operating modes, recording data both inside the cryomodule and across the bayonet can circuits. Thermal-acoustic oscillations were eliminated by replacing the original G10 cooldown-valve stem with a stainless-steel stem fitted with wipers. A newly developed Python script automated acquisition of ACNET data, performed real-time heat-load calculations, and generated plots and tables that were posted to the electronic logbook within minutes, vastly reducing manual effort and accelerating feedback between SRF and cryogenics teams. Analysis showed that JT heat-exchanger effectiveness and temperature stratification in the two-phase and relief piping strongly influence the observed loads and helped isolate sources of excess heat. The campaign demonstrates that rigorous pre-test planning, real-time diagnostics, and automated reporting can improve both accuracy and efficiency, providing a template for future PIP-II cryomodule tests and for implementing targeted heat-load mitigations.

Porwisiak, D. [Fermilab; Wroclaw Tech. U.] (ORCID:↗
DOE OSTI2021

Thermal Evaluation of the SAVY-4000 1 Quart Container at High Heat Loads

The SAVY-4000 Safety Analysis Report (SAR) was published in 2013 which established the design life of the container series through physical testing that meets applicable requirements from DOE M 441.1-1, Nuclear Material Packaging Manual. One critical requirement in DOE M 441.1-1 is to set a maximum heat load for the entire series to ensure that throughout the lifetime of the container, each of the components still performs within manufacture specifications. The original maximum decay heat limit has been defined within the SAVY-4000 SAR, which was accomplished by completing a series of tests that heat loaded the SAVY-4000 series and measured the steady state temperature and graded it against manufacture specifications. The container series is comprised of a corrosion resistant 316L stainless steel containment boundary, ceramic composite filter for the prevention of radiological particulate release and a chemically stable O-ring made of Viton ® . Currently, the SAVY 4000 maximum decay heat load is set at 25 Watts and the heat load expected during normal handling and storage is considered sufficient that the SAVY 4000 container requirements will not be the limiting factor for storage of most common material in use at TA-55, e.g. weapons grade oxide, americium, Pu-238 oxide and encapsulated heat sources. The SAVY 4000 lifetime was originally set as 5 years within the SAVY-4000 SAR, but in July 2019 the lifetime was extended to 15 years through a technical basis justification approved by the Department of Energy (DOE) Los Alamos Field Office. The 25 Watt limit applies to all SAVY 4000 container sizes; 1-quart, 2-quart, 3-quart, 5-quart, 8-quart, 12-quart, 5-gallon, and 10-gallon.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2025

Surface Heat Load Analysis Due to Plasma Thermal Radiation on Equatorial Port 09

This paper reports calculated surface heat load owing to plasma thermal radiation, which will be applied to the surfaces of Equatorial Port 09 (EP09) diagnostic shield modules (DSMs) for thermal analysis during normal operation. The calculation assumes that the thermal energy will deposit uniformly in all directions from the plasma to the adjacent components and environment (i.e. gray body radiation). Assuming the temperature for the plasma surface, calculated view factors are used to determine the allocation of thermal energy to each component. The analysis provides an initial assessment of the thermal radiation heat load on the DSMs to be checked in structural/thermal analyses to verify significance. In conclusion, the designs of the EP09 components are still in the early preliminary phase, and changes are expected in the future.

ANSYS↗
DOE OSTI2024

Optimization of static heat loads of the PIP-II cryomodules based on prototype HB650 cryomodule test results

During the first cool down of the prototype HB650 cryomodule (pHB650 CM), high static heat loads have been measured compared to the estimation. Several analysis and calculations have been performed to explain this difference which led to cool down this cryomodule two additional times. Before each cool down, repairs and upgrades have been done, and instrumentations were added to identify the issues and quantify their impact on the heat loads. Based on these findings, the production cryomodule design and assembly process have been updated to align the future heat loads measurements with the estimations.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

Electromagnetic turbulence simulation of tokamak edge plasma dynamics and divertor heat load during thermal quench

Abstract The edge plasma turbulence and transport dynamics, as well as the divertor power loads during the thermal-quench phase of tokamak disruptions, are numerically investigated with BOUT++’s flux-driven six-field electromagnetic turbulence model. Here, transient yet intense particle and energy sources are applied at the pedestal top to mimic the plasma power drive at the edge induced by a core thermal collapse, which flattens the core temperature profile. Interesting features, such as surging of divertor heat load (up to 50 times) and broadening of heat-flux width (up to four times) on the outer-divertor target plate, are observed in the simulation, in qualitative agreement with experimental observations. The dramatic changes in divertor heat load and width are due to the enhanced plasma turbulence activities inside the separatrix. Two cross-field transport mechanisms, namely, the E × B turbulent convection and the stochastic parallel advection/conduction, are identified to play important roles in this process. First, an elevated edge pressure gradient drives instabilities and subsequent turbulence in the entire pedestal region. The enhanced turbulence not only transports particles and energy radially across the separatrix via the E × B convection, which causes the initial divertor heat-load burst, but it also induces amplified magnetic fluctuation B ˜ . Once themagnetic fluctuation is large enough to break the magnetic flux surface, magnetic flutter effect provides an additional radial transport channel. In the late stage of our simulation, | B ˜ r / B 0 | reaches to 10 −4 level that completely breaks magnetic flux surfaces such that stochastic field lines are directly connecting pedestal top plasma to the divertor target plates or first wall, further contributing to the divertor heat-flux width broadening.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2025

Techno-economic feasibility of borehole thermal energy storage system connected to geothermal heat pumps for seasonal heating load of two buildings in Fairbanks, Alaska

Borehole thermal energy storage (BTES) is an effective solution for managing imbalanced heating and cooling loads in cold regions. This study evaluated the long-term feasibility of a BTES system in the Fairbanks area, Alaska, through building energy modeling, resource characterization, and numerical modeling. The system was designed to store waste heat from a nearby coal power plant during summer and provide thermal energy during winter to geothermal heat pumps supplying heating loads in two buildings. Heating load profiles were modeled for the buildings using EnergyPlus, and the results indicated the annual heating load was 5.6 times greater than the cooling load. 40 borehole heat exchangers were pre-designed approximately 100 m away from the two buildings in terms of land availability and regulatorily optimized depth. The 20-year performance of the designed BTES system under two operational scenarios—one with a 5-year preheating period and one without—was numerically modeled using subsurface temperature and properties characterized through the literature review and thermal response tests. Both scenarios demonstrated that the BTES has the capacity to fully cover the heating loads in the two buildings throughout the 20-year lifetime. Production temperatures at central wells were 33 % higher on average than at outer wells in both scenarios. The 5-year preheating period increased subsurface and extraction temperatures, and correspondingly annual average and total thermal energy production was higher for 8 years than in the scenario without the preheating period. These results highlight the long-term reliability and sustainability of the BTES system in meeting heating demands over its lifetime, with the preheating period offering potential performance improvements. Implementing the BTES system in cold regions with high heating demand, such as Fairbanks, Alaska, could provide a long-term, sustainable energy solution for managing imbalanced heating and cooling loads.

15 GEOTHERMAL ENERGY↗
DOE OSTI2025

Real time heat load calculation software based on EPICS for Fermilab PIP-II CM tests

Fermilab has a project to improve the proton beam energy which is called PIP-II (the 2nd Proton Improvement Plan). There is a superconducting linear accelerator, LINAC, to improve the proton beam power and the LINAC consists of 5 types of cryomodules (CM), 1 HWR CM, 2 SSR1 CM, 4 SSR2 CM, LB650 CM, and HB650 CM. The prototypes of these cryomodules are being tested at Fermilab’s CryoModule Test Facility (CMTF). Heat load measurements are an important part of the prototype CM testing. The CMTF cryogenic control system was developed based on the ACNET (Accelerator Control NETwork) for CM testing for other projects, but the PIP-II cryogenic control system will be implemented using the Experimental Physics and Industrial Control System (EPICS). As part of the prototype CM testing campaign an EPICS based control system has been implemented at CMTF. This EPICS cryogenic control system includes real time heat load calculation software utilizing the Fortran implementation of Hepak. This paper details the real time heat load calculation software developed for the prototype CM testing including the first results from the HB 650 CM.

Yoon, S. [Fermilab]↗
DOE OSTI2026

Real time heat load calculation software based on EPICS for Fermilab PIP-II CM tests

Fermilab has a project to improve the proton beam energy which is called PIP-II (the 2nd Proton Improvement Plan). There is a superconducting linear accelerator, LINAC, to improve the proton beam power and the LINAC consists of 5 types of cryomodules (CM), 1 HWR CM, 2 SSR1 CM, 4 SSR2 CM, LB650 CM, and HB650 CM. The prototypes of these cryomodules are being tested at Fermilab’s CryoModule Test Facility (CMTF). Heat load measurements are an important part of the prototype CM testing. The CMTF cryogenic control system was developed based on the ACNET (Accelerator Control NETwork) for CM testing for other projects, but the PIP-II cryogenic control system will be implemented using the Experimental Physics and Industrial Control System (EPICS). As part of the prototype CM testing campaign, an EPICS based control system has been implemented at CMTF. This EPICS cryogenic control system includes real-time heat load calculation software utilizing the Fortran implementation of Hepak. This paper details the real time heat load calculation software developed for the prototype CM testing including the first results from the HB650 CM.

Yoon, S. [Fermilab]↗
DOE OSTI2023

Multi-objective optimization of CEBAF heat load management and trip rates using AI/ML

The goal of this project is to investigate the use of RL to simultaneously optimize the cryogenic heat load and trip rate of the CEBAF linacs and make it generic to solve multi-objective problems that will enable its application at other Department of Energy (DOE) facilities with similar challenges. The existing approach optimizes the gradient distribution to minimize the trip rate and does not take into account the total heat load. A secondary objective of the project is the develop a framework to correct cavity quality curves (Q-curves) or RF-heat to Gradient relation curves for individual cavities. These curves are currently obtained using historical measurements and may have changed their behavior due to various events. Correction in these curves will allow us to accurately approximate the total RF heat generated by the linacs which is critical for the optimization.

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

Wire-coil insert optimization for high-heat-load/flux synchrotron components

Many synchrotron components require high levels of internal-flow, forced-convection heat transfer to minimize surface temperatures, thermal gradients, and thermally induced stress on high-power beam-interacting surfaces. Wire-coil inserts, physically similar to a common spring, are mechanically fitted inside of component cooling passages to optimize heat transfer performance. They are routinely used in Advanced Photon Source (APS) front end and beamline high-heat-load/flux components to significantly enhance convection heat transfer-up to 400% compared to plain open passages. This has the additional benefit of greatly reducing coolant flow requirements for these components. Using several cooling passage sizes, five different wire sizes, and a range of pitch values, an experimental investigation conducted at the APS has determined the average heat transfer coefficient and resulting pressure loss as a function of water flow rate for 65 different wire-coil inserts. Data from this study have been non-dimensionalized and generalized to yield relationships that can be used to determine the heat transfer performance and resulting pressure loss for any given wire-coil insert that may be used at the APS. Through data reduction, the wire-coil insert characteristic dimensions have also been optimized to yield the highest heat transfer enhancement while minimizing the coolant flow requirements. These generalized expressions for wirecoil inserts will be presented, and they can be used by scientists and engineers during the component design process to evaluate achievable heat transfer performance and associated pressure loss, aiding in the establishment of optimized operating parameters and cooling passage flow distribution schemes.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

Prototype HB650 Cryomodule Heat Loads Simulations

During the design stages of the PIP-II cryomodules, many analytical calculations and FEA have been performed on simpler geometry in order to estimate the heat loads and also to optimize the design. To better analyze the cryomodule cold tests, simulations have been performed with MATLAB to determine the temperature of the main components during cool down and to determine the heat loads of the cryomodule. These simulations have been applied to the High Beta 650 MHz prototype cryomodule design and compared to the cold tests performed on it.

43 PARTICLE ACCELERATORS↗
DOE OSTI2026

On how avalanches penetrate the SOL and broaden heat loads

Recent experiments reported a correlation between power law core temperature spectra and Dα emission, suggesting that heat avalanches penetrate the SOL. This paper derives a threshold criterion for avalanche penetration using a reduced model. Avalanches with ($\bigtriangledown$$\tilde{T}$) rms > $\bigtriangledown$$\tilde{T}$ crit at the separatrix are predicted to penetrate, and so broaden the SOL and heat load distribution. $\bigtriangledown$$\tilde{T}$ crit is ~ 1/$τ$ ∥ , where $τ$ ∥ is the parallel heat flow time through the SOL. Penetration occurs when avalanches are strong enough to steepen sufficiently to shock at the separatrix. A positive correlation is found between the nonlinear drive for steepening and the penetration depth. In particular, penetration depth exceeds that of the heuristic drift limit when shocks form. Implications for numerical and physical experiments are also discussed.

SOL heat load↗
DOE OSTI2020

Compensation of heat load deformations using adaptive optics for the ALS upgrade: a wave optics study

In this paper, a realistic wave optics simulation method has been developed to study how wavefront distortions originating from heat load deformations can be corrected using adaptive X-ray optics. Several planned soft X-ray and tender X-ray insertion-device beamlines in the Advanced Light Source upgrade rely on a common design principle. A flat, first mirror intercepts the white beam; vertical focusing is provided by a variable-line-space monochromator; and horizontal focusing comes from a single, pre-figured, adaptive mirror. A variety of scenarios to cope with thermal distortion in the first mirror are studied by finite-element analysis. The degradation of the intensity distribution at the focal plane is analyzed and the adaptive optics that correct it is modeled. The range of correctable wavefront errors across the operating range of the beamlines is reported in terms of mirror curvature and spatial frequencies. The software developed is a one-dimensional wavefront propagation package made available in the OASYS suite, an adaptable, customizable and efficient beamline modeling platform.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗
DOE OSTI2021

Constructing a new predictive scaling formula for ITER's divertor heat-load width informed by a simulation-anchored machine learning

Understanding and predicting divertor heat-load width λq is a critically important problem for an easier and more robust operation of ITER with high fusion gain. Previous predictive simulation data for λ q using the extreme-scale edge gyrokinetic code XGC1 [S. Ku et al., Phys. Plasmas 25, 056107 (2018)] in the electrostatic limit under attached divertor plasma conditions in three major US tokamaks [C. S. Chang et al., Nucl. Fusion 57, 116023 (2017)] reproduced the Eich and Goldston attached-divertor formula results [formula #14 in T. Eich et al., Nucl. Fusion 53, 093031 (2013) and R. J. Goldston, Nucl. Fusion 52, 013009 (2012)] and furthermore predicted over six times wider λ q than the maximal Eich and Goldston formula predictions on a full-power (Q = 10) scenario ITER plasma. After adding data from further predictive simulations on a highest current JET and highest-current Alcator C-Mod, a machine learning program is used to identify a new scaling formula for λ q as a simple modification to the Eich formula #14, which reproduces the Eich scaling formula for the present tokamaks and which embraces the wide λ q XGC for the full-current Q = 10 ITER plasma. Additionally, the new formula is then successfully tested on three more ITER plasmas: two corresponding to long burning scenarios with Q = 5 and one at low plasma current to be explored in the initial phases of ITER operation. The new physics that gives rise to the wider λ q XGC is identified to be the weakly collisional, trapped-electron-mode turbulence across the magnetic separatrix, which is known to be an efficient transporter of the electron heat and mass. Electromagnetic turbulence and high-collisionality effects on the new formula are the next study topics for XGC1.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗