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DOE OSTI2023

Effect of outer-cylinder rotation on the radially heated Taylor–Couette flow

A Taylor–Couette setup with radial heating is considered where a Boussinesq fluid is sheared in the annular region between two concentric, independently rotating cylinders maintained at different temperatures. Linear stability analysis is performed to determine the Taylor number for the onset of instability. Two radius ratios corresponding to wide and thin gaps with several rotation rate ratios are considered. The rotation of the outer cylinder is found to have a general stabilizing effect on the stability threshold as compared to pure inner-cylinder rotation, with a few exceptions. The radial heating sets up an axial flow which breaks the reflection symmetry of isothermal Taylor–Couette flow in the axial coordinate. This symmetry breaking separates linear stability thresholds, and we find the fastest growing modes with both positive and negative azimuthal numbers for different parameters. Another important finding of the current study is the discovery of unstable modes in the Rayleigh-stable regime. Furthermore, closed disconnected neutral curves (CDNCs) are observed for both wide and thin gaps which can separate from or merge into open neutral–stability curves. Alternatively, CDNCs can also morph into open neutral stability curves as the rotation rate ratio is changed. CDNCs are observed to be sensitive to changes in control parameters, and their appearance/disappearance is shown to induce discontinuous jumps in the critical Taylor number. Finally, for both wide and thin gaps, the fastest-growing modes found in the pure corotation case are shown to have their origins in the instability islands at smaller values of rotation rate ratios.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2022

Gastight rotating cylinder electrode: Toward decoupling mass transport and intrinsic kinetics in electrocatalysis

Abstract Decoupling and understanding the various mass, charge, and heat transport phenomena involved in the electrocatalytic transformation of small molecules (i.e., CO 2 , CO, H 2 , N 2 , NH 3 , O 2 , and CH 4 ) is challenging but it can be readily achieved using dimensionless quantities (i.e., Reynolds, Sherwood, Schmidt, Damköhler, Nusselt, Prandtl, and Peclet Numbers) to simplify the characterization of systems with multiple interacting physical phenomena. Herein we report the development of a gastight rotating cylinder electrode cell with well‐defined mass transport characteristics that can be applied to experimentally decouple mass transfer effects from intrinsic kinetics in electrocatalytic systems. The gastight rotating cylinder electrode cell enables the dimensionless analysis of electrocatalytic systems and should enable the rigorous research and development of electrocatalytic technologies.

Jang, Joonbaek↗

DOE OSTI2022

Quantifying transport and electrocatalytic reaction processes in a gastight rotating cylinder electrode reactor via integration of Computational Fluid Dynamics modeling and experiments

Understanding the complexity of the multiple processes of mass, momentum, charge, and heat transport, and how these affect reaction kinetics at the electrode/electrolyte interface is one of the major challenges in the field of energy and catalysis. The rapid and rational scale-up of electrocatalytic systems to industrial scales require a detailed understanding of nonlinear transport-reaction processes, accessible only through the building of multi-physics models that capture with high fidelity the complexity of real-world devices. The gastight rotating cylinder electrode (RCE) reactor is a promising lab-scale tool that can decouple transport from intrinsic kinetics to generate data for first-principle models useful in the design of industrial, electrochemical reactors. Computational Fluid Dynamics (CFD) studies have previously been used to investigate the bulk flow in RCE reactors for simple corrosion and electroplating processes. However, the quantification of changes in local concentration within the viscous layer where catalysis takes place requires capturing the correct flow conditions inside the hydrodynamic boundary layer near the surface of the electrode. Further, this requires simulations with spatial resolution in the nm and μm scale and temporal resolutions between ms and s scales that are similar to the timescales for reactions on the electrode surface. In this study, experimental electrocatalysis is combined with CFD modeling to elucidate and parameterize the hydrodynamics in a gastight RCE reactor. CFD simulations of the electrochemical ferricyanide reduction reaction under mass transport limited conditions are used to evaluate the validity of the CFD model parameters by comparing calculated dimensionless mass transport descriptors to dimensionless correlations obtained experimentally. Justifications for assumptions and details of the simulation methods used in this study are presented to provide a detailed understanding of the effect that each model parameter has on the ability to accurately simulate electrocatalysis in RCE systems. The simulation methodology reported here is a first step towards the development of multi-scale models for the study of transport dependent electrocatalytic processes, such as the electrochemical transformation of CO 2 to fuels and chemicals.

42 ENGINEERING↗

DOE OSTI2024

Rotating cylinder electrode in reactive CO 2 capture: Identifying active C species via transport, VLE models and kinetics

Here, this article explores technical challenges and potential methodologies for understanding electrochemical Reactive CO 2 Capture (RCC) mechanisms. RCC offers potential energy cost advantages by directly converting captured CO 2 into fuels and chemicals, unlike traditional carbon capture and utilization (CCU) processes that require sequential capture, concentration, and compression. However, direct conversion of captured CO 2 introduces complexity due to additional equilibrium buffer reactions, making it challenging to identify active species for reduction in electrochemical studies. This article discusses methods to integrate transport, thermodynamics, and kinetics concepts to identify active carbon sources in RCC. Vapor‐Liquid Equilibrium (VLE) and transport models are validated against experimental results obtained in a gastight rotating cylinder electrode reactor and are shown as useful tools for studying RCC in heterogeneous electrocatalysts across different capture agents, solvents, and temperatures. This article establishes an experimental framework for advancing research in electrochemical RCC.

Electrocatalysis↗

DOE OSTI2025

Thermovelocimetric characterization of liquid metal convection in a rotating slender cylinder

Rotating turbulent convection occurs ubiquitously in natural convective systems encompassing planetary cores, oceans and atmospheres, as well as in many industrial applications. While the global heat and mass transfer of water-like rotating Rayleigh–Bénard convection is well-documented, the dynamics in low-Prandtl-number liquid metals remain less understood. In this study, we experimentally investigate rotating Rayleigh-Bénard convection in liquid gallium (Prandtl number Pr ≈ 0.027) within a slender cylinder (diameter-to-height aspect ratio Γ = D/H =1/2) using novel thermovelocimetric diagnostic techniques that integrate simultaneous multi-point thermometry and ultrasonic Doppler velocity measurements. Our results reveal the formation of a stable, global-scale azimuthal wavenumber m = 2 quadrupolar vortex at low supercriticality. We propose that enhanced wall modes facilitated by the slender cylinder geometry interact with the bulk flow to create these large-scale axialized vortices. Furthermore, our findings imply a distinct scaling behavior for the wall-mode precession frequency in liquid metals, extending previous results obtained for moderate-Pr fluids. In conclusion, this provides new insights into wall-bulk coupling mechanisms of low-Pr rotating convective turbulence.

Magnetohydrodynamics↗

DOE OSTI2021

Computing of Fluidic Forces in Rotating Cylinders with Application to Active Magnetic Bearing Control

Oak Ridge National Laboratory (ORNL) has been engaged to develop molten salt technologies. Molten salts are chemically aggressive liquids that operate at high temperatures. As part of this activity, ORNL designed a molten salt pump for molten salt that has no seals and that operates immersed in the salt. To minimize wear on rotating components, the pump uses active magnetic bearings (AMBs) to support the shaft and rotor. The pump is centrifugal and is oriented horizontally (A. Melin, 2013).

42 ENGINEERING↗

DOE OSTI2023

Machine learning-based ethylene and carbon monoxide estimation, real-time optimization, and multivariable feedback control of an experimental electrochemical reactor

Electrochemical reduction of CO 2 gas is a novel CO 2 utilization technique that has the potential to mitigate the global climate crisis caused by anthropogenic CO 2 emissions, and enable the large-scale storage of energy generated from renewable sources in the form of carbon-based chemicals and fuels. However, due to the complexity of the electrochemical reactions, the explicit first-principles models for CO2 reduction are not available yet, and there has been a limited effort to develop process modeling, optimization and control of CO 2 electrochemical reactors. To this end, a rotating cylinder electrode (RCE) reactor has been constructed at UCLA to understand the mass transfer and reaction kinetics effects separately on the productivity. In the RCE reactor, the applied potential strongly influences the reaction energetics and the electrode rotation speed affects the hydrodynamic boundary layer and modifies the film mass transfer coefficient, which involves convective and diffusive transport. Further, the present work aims to develop a multi-input multi-output (MIMO) control scheme for the RCE reactor that integrates techniques from artificial and recurrent neural network modeling, nonlinear optimization, and process controller design. Specifically, production rates of two products from the experimental reactor, ethylene and carbon monoxide, are controlled by manipulating two inputs, applied potential and catalyst rotation speed. Process dynamics and controllability are analyzed, a feedback control strategy is designed and the controllers are tuned accordingly. The experimental electrochemical cell is employed to gather data for process modeling and implement the multivariable control system. Finally, the experimental results are presented which demonstrate excellent closed-loop performance by the control system and regulation of the outputs at three different set-points including an economically-optimal set-point.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Electrolyzers in focus: advances in CO 2 electrolyzer designs

Electrochemical CO 2 reduction (ECR) remains a viable method to reintegrate anthropogenic CO 2 into current energy infrastructures through its conversion into commodity chemicals. To facilitate the integration of ECR, electrochemical devices called electrolyzers must be implemented to overcome the inherent limitations that exist in current ECR experiments, namely kinetics and mass transport. In this review, we outline the current and advancing designs in ECR electrolyzers, with a focus on the following five electrochemical devices: membrane electrode assemblies (MEA), flow cell (FC), rotating disk electrode (RDE), rotating ring-disk electrode (RRDE), and rotating cylinder electrode (RCE). We highlight the tunable components of each electrolyzer with a forward outlook on the optimization and relevance of electrolyzer designs in upcoming ECR applications.

CO2 reduction↗

DOE OSTI2025

Lithium Divertor Targets and Walls for the ASTER Liquid Stellarator Reactor, Distributed Divertor

Stellarators may have advantages for certain liquid metal options as Plasma Facing Components (PFC) for divertor targets and first walls due to the wide range of possible magnetic configurations, which additionally are free of disruptions and fast field variations. In a previous work (V. Queral et al., IEEE Trans. Plasma Sci. 52, 2024), a concept of stellarator reactor (ASTER-CP) based on swirling Li-molten salts and liquid lithium floating on the molten salt as PFC was presented. The divertor matters were not studied then and, thus, they are being studied and experimentally tested now. The ASTER-CP reactor concept, the initial liquid metal experiments and potential concepts for the ASTER-CP divertor and first wall are reported. Concerning the experiments, several small scale experiments of galinstan in a small rotating cylinder under magnetic field have been produced, including one experiment with high viscosity galinstan-mixture for increased thickness of layer. An experiment of floating lithium on the molten salt LiCl-PbCl2 gave fast volatilization/decomposition of the molten salt. Particularly for divertors, the traditional free-flow, Capillary Porous Systems and ‘divertorlets’ have been studied for application to ASTER-CP. Surface waves (hot spots), lack of enough surface fluid turbulence and excessive fluid speed are the main issues found in fast free-flow. The perhaps original concept of Distributed Divertor and Equi-power Surface is tentatively proposed and studied, taking advantage of stellarator fields and low recycling regime.

distributed divertor↗

DOE OSTI2024

On a High-Mirror Stellarator Reactor Exploratory Concept With Neutrons Concentrated on Centrifuge Liquids

In the framework of fusion energy research based on magnetic confinement, stellarators allow numerous degrees of freedom for the design of the magnetic trap and plasma shape. Taking advantage of these features, some plasma shapes might benefit several of the many integrated elements involved in commercial fusion reactors, like, e.g., decreasing the number, mass and complexity of replaced activated in-vessel components (IVC) (i.e., by using liquids), extraction of large power, tritium generation, and remote maintenance. Certainly, free-surface liquid materials were proposed for tokamaks and field-reversed configuration (FRC) to try to improve some of such elements, i.e., in advanced power extraction (APEX) studies. Some reactor-relevant quasi-isodynamic (QI) magnetic configurations exhibit a relatively straight sector of plasma and high magnetic mirror. The combination of those elements and possibilities in a single stellarator reactor concept might have some advantages, in spite of the uncertainties due to the current low technological readiness level (TRL). The proposed and studied reactor concept is based on a vacuum vessel having short curved sectors and longer wide cylindrical sectors, which encloses a high-mirror low-vertical-excursion magnetic configuration, and swirling liquids or rotating cylinders, which centrifuge molten Li salts located at the low field region. Thus, the molten salts (if possible covered by a thin layer of liquid lithium) would be located on the internal perimeter of the cylinder, to act as particle exhaust (except for helium), neutron power extractor, and tritium breeder. The high-mirror feature tries to concentrate the neutron power at the cylindrical sectors, which might avoid using breeding materials at the curved sectors. The different elements of the concept are exploratorily studied and defined, and the difficulties assessed.

centrifuge↗

DOE OSTI2022

Alkaline cation enrichment and water electrolysis to provide CO 2 mineralization and global-scale carbon management

Provided herein are methods of removing carbon dioxide from an aqueous stream or gaseous stream by: contacting the gaseous stream comprising carbon dioxide, when present, with an aqueous solution comprising ions capable of forming an insoluble carbonate salt; contacting the aqueous solution comprising carbon dioxide with an electroactive mesh that induces its alkalinization thereby forcing the precipitation of a carbonate solid from the solution and thereby the removal of dissolved inorganic carbon by electrolysis; and removing the precipitated carbonate solids from the solution, or the surface of the mesh where they may deposit. Also provided herein are flow-through electrolytic reactors comprising an intake device in fluid connection with a rotating cylinder comprising an electroactive mesh, and a scraping device and/or liquid-spray based device for separating a solid from the mesh surface.

Sant, Gaurav↗

DOE OSTI2020

Angular Momentum in Rotating Superfluid Droplets

The angular momentum of rotating superfluid droplets originates from quantized vortices and capillary waves, the interplay between which remains to be uncovered. Here, the rotation of isolated submicrometer superfluid 4 He droplets is studied by ultrafast x-ray diffraction using a free electron laser. The diffraction patterns provide simultaneous access to the morphology of the droplets and the vortex arrays they host. In capsule-shaped droplets, vortices form a distorted triangular lattice, whereas they arrange along elliptical contours in ellipsoidal droplets. The combined action of vortices and capillary waves results in droplet shapes close to those of classical droplets rotating with the same angular velocity. The findings are corroborated by density functional theory calculations describing the velocity fields and shape deformations of a rotating superfluid cylinder.

O'Connell, Sean M.O.↗

DOE OSTI2024

Taylor-Couette Flow Modeling (Rev.1)

The Taylor-Couette Flow is a form of viscous flow in which fluid flows between two cylindrical walls with a prescribed rotation. A diagram is shown on the right (Figure 1) where Ω is the rotational velocity, H is the distance between the two cylinders, R is the radius the outer cylinder, r is the radius of the inner cylinder and L is the length of the cylinders. When the rotating inner cylinder reaches a critical velocity, the flow of the liquid becomes unstable and creates vortices in between the layers. In this experiment, the Taylor-Couette cylinders were modeled so that the vortices would be created after reaching a critical velocity. After the initial experiment, the velocity of the inner cylinder was decreased and increased to look at how the results changed.

42 ENGINEERING↗

DOE OSTI2023

Thermal Spray toolpath development for a capped cylinder (“cake pan”) substrate

A near net shape coating is desired to be applied to the outer surface of a capped cylinder (“cake pan”) type substrate using thermal spray technology. A capped cylinder geometry is more complex than simple coupon-level substrate substrates (e.g., flat panels, cylinders) and thus requires a more complex toolpath to deposit a uniform coating. This report documents a practical theoretical approach to calculating relative torch-to-substrate speeds for coating the cylindrical, corner, and cap region of a rotating capped cylinder based on fundamental thermal spray toolpath principles. A preliminary experimental test deposited a thermal spray coating onto a mock substrate using toolpath speeds calculated by the theoretical approach proposed. The mock substrate was metallographically inspected to assess coating uniformity across the cylindrical, corner, and cap region. Inspection of the mock substrate revealed qualitatively uniform coating microstructure and thickness where theoretically predicted, demonstrating the viability of the proposed toolpath method and associated calculations. Pathways forward to optimizing coating uniformity at the cap center are proposed as near term suggested future work.

42 ENGINEERING↗

DOE OSTI2024

Innovative control mechanism for research and test reactors using mandrel-shaped control rods

Research and test reactors have historically played a pivotal role in supporting the initial development of nuclear reactors. They continue to provide essential data for enhancing fuel designs and material knowledge. However, with many such reactors aging and the growing demand for data to bolster advanced reactor development, it is more necessary to research potential design attributes of the next generation of research and test reactors. For test reactors dedicated to fuel and material testing, the design of control mechanisms significantly influences the stabilization of neutron flux levels in irradiation positions while sustaining criticality. This study presents an innovative control mechanism for potential research and test reactor designs. It employs small absorber rods that move in opposite axial directions to maintain axial symmetry of power and neutron flux during burnup cycles. These rods maximize reactivity worth while also offering flexibility to flatten the radial power distribution. An axial translation of the control mechanisms’ absorbers, as compared to the rotational movement of absorbers in control cylinders, also provides a benefit to available excess reactivity and cycle length. Additionally, this work utilizes a simplified core model of the Advanced Test Reactor to assess the performance of this control mechanism. Compared to the current control system based on rotating control cylinders, the new control mechanism has the potential to enhance, or at least maintain, neutronic performance parameters in this reactor design.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2022

Rotational flexural strength of cylindrical brittle specimens

Conventional static flexural strength testing of brittle cylindrical rods only subjects a small fraction of the entire specimen's area or volume to the maximum tensile stress. Thus, a nonconservative measured strength likely results since most flaws on the surface or in the bulk are not subjected to a sufficiently high tensile stress that can cause fracture. Here, to mitigate this, a rotational flexural tester and corresponding test method were developed whereby rotation and monotonically increasing three-point flexure were superimposed to investigate fracture response of solid glass cylinders. This combination of rotation and flexure subjects more area and volume of a cylindrical test specimen to tensile stress than a standard static (nonrotating) flexural test. As anticipated, failure stresses were lower for the rotational flexural test. Expressions for effective area and volume are provided for rotating solid rods and tubes subjected to three-point, four-point, uniform, and uniformly distributed load bending configurations.

36 MATERIALS SCIENCE↗

DOE OSTI2022

Reducing Memory Consumption in Calico with Shared Memory

This document details the work to reduce memory consumption in Calico. Calico is SimTools’ Constructive Solid Geometry (CSG) and geometry painting library. It is primarily used to paint material volume fractions in the Eulerian meshes of the physics codes. Calico provides point-in-body checks for the geometry supplied by an Oso model, which are then aggregated by the host codes. In addition, Calico can be used to build Oso models and is used by Ingen for that purpose. Oso models, and thus Calico, provide support for various CSG primitives such as spheres, cylinders, surfaces generated by rotating tabular curve data, and STL files as well as binary combinations of those primitives. Prior to refactoring Calico will run out of memory on CTS-1 machines when 36 MPI ranks are used per node when reading STL models on the order of 1.5 GB. This limitation is a bottleneck in designer workflow. This problem has been alleviated through the use of data structures to both reduce memory consumption and to leverage MPI-3 shared memory. This report details the data structures targeted for refactoring in Calico, the methods and implementation details for reducing memory consumption and leveraging shared memory, and results for one test problem. Results show a memory reduction when loading a 1 GB STL file by a factor of 27.5, from 93.4 to 3.4 GB.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2023

Taylor–Couette flow for astrophysical purposes

A concise review is given of astrophysically motivated experimental and theoretical research on Taylor–Couette flow. The flows of interest rotate differentially with the inner cylinder faster than the outer, but are linearly stable against Rayleigh’s inviscid centrifugal instability. At shear Reynolds numbers as large as 10 6 , hydrodynamic flows of this type (quasi-Keplerian) appear to be nonlinearly stable: no turbulence is seen that cannot be attributed to interaction with the axial boundaries, rather than the radial shear itself. Direct numerical simulations agree, although they cannot yet reach such high Reynolds numbers. This result indicates that accretion-disc turbulence is not purely hydrodynamic in origin, at least insofar as it is driven by radial shear. Theory, however, predicts linear magnetohydrodynamic (MHD) instabilities in astrophysical discs: in particular, the standard magnetorotational instability (SMRI). MHD Taylor–Couette experiments aimed at SMRI are challenged by the low magnetic Prandtl numbers of liquid metals. High fluid Reynolds numbers and careful control of the axial boundaries are required. The quest for laboratory SMRI has been rewarded with the discovery of some interesting inductionless cousins of SMRI, and with the recently reported success in demonstrating SMRI itself using conducting axial boundaries. Some outstanding questions and near-future prospects are discussed, especially in connection with astrophysics.

79 ASTRONOMY AND ASTROPHYSICS↗