This paper advances a vision for plasma facing components (PFCs) that includes the following points. The solution for plasma facing materials likely consists of engineered structures in which the layer of plasma facing material (PFM) is integrated with an engineered structure that cools the PFM and may also transition with graded composition. The key to achieving this PFC architecture will likely lie in advanced manufacturing methods, e.g., additive manufacturing, that can produce layers with controlled porosity and features such as micro-fibers and/or nano-particles that can collect He and transmutation products, limit tritium retention, and do all this in a way that maintains adequate robustness for a satisfactory lifetime. This vision has significant implications for how we structure a development program.
Past numerical investigations of the performance of porous media to enhance heat transfer in helium-cooled devices neglected the susceptibility of multi-channel heat sinks to parallel flow instabilities even though experimental evidence suggests it may be a problem for narrow channel devices. In previous work, our simulations have shown that helium micro-jets do not experience changes in flow distribution due to non-uniform heating. However, jets are difficult to fabricate for large area refractory metal components. The same is not true for narrow channel devices filled with porous media. Although these refractory devices are easier to fabricate, the effects of downstream hot gas expansion can influence the incoming flow distribution in multi-channel configurations.
Due to a lack of prototypical experimental data, little is known about the off-normal behavior of recently proposed divertor jet cooling concepts. This article describes a computational fluid dynamics (CFD) study on two jet array designs to investigate their susceptibility to parallel flow instabilities induced by non-uniform heating and large increases in the helium outlet temperature. The study compared a single 25-jet helium-cooled modular divertor (HEMJ) thimbleand a micro-jet array with 116 jets. Both havepure tungsten armor and atotal mass flow rate of 10 g/s at a 600°C inlet temperature. We investigated flow perturbations caused by a 30 MW/m2 off-normal heat flux applied over a 25 mm2 area in addition to the nominal 5 MW/m2 applied over a 75 mm2 portion of the face. The micro-jet array exhibited lower temperatures and a more uniform surface temperature distribution than the HEMJ thimble. We also investigated the response of a manifolded nine-finger HEMJ assemblyusing the nominal heat flux and a 274 mm2 heated area. For the 30 MW/m2 case, the micro-jet array absorbed 750 W in the helium with a maximum armor surface temperature of 1280°C and a fluid/solid interface temperature of 801°C. The HEMJ absorbed 750 W with a maximum armor surface temperature of 1411°C and a fluid/solid interface temperature of 844°C.For comparison, both the single HEMJ finger and the micro-jet array used 5-mm-thick tungsten armor. The ratio of maximum to average temperature and variations in the local heat transfer coefficient were lower for the micro-jet array compared to the HEMJ device. Although high heat flux testing is required to validate the results obtained in these simulations, the results provide important guidance in jet design and manifolding to increase heat removal while providing more even temperature distribution and minimizing non-uniformity in the gas flowand thermal stresses at the armor joint.
In this study, due to a lack of prototypical experimental data, little is known about the off-normal behavior of recently proposed divertor jet cooling concepts. This article describes a computational fluid dynamics (CFD) study on two jet array designs to investigate their susceptibility to parallel flow instabilities induced by non-uniform heating and large increases in the helium outlet temperature. The study compared a single 25-jet helium-cooled modular divertor (HEMJ) thimble and a micro-jet array with 116 jets. Both have pure tungsten armor and a total mass flow rate of 10 g/s at a 600 °C inlet temperature. We investigated flow perturbations caused by a 30 MW/m2 off-normal heat flux applied over a 25 mm2 area in addition to the nominal 5 MW/m2 applied over a 75 mm2 portion of the face. The micro-jet array exhibited lower temperatures and a more uniform surface temperature distribution than the HEMJ thimble. We also investigated the response of a manifolded nine-finger HEMJ assembly using the nominal heat flux and a 274 mm2 heated area. For the 30 MW/m2 case, the micro-jet array absorbed 750 W in the helium with a maximum armor surface temperature of 1280 °C and a fluid/solid interface temperature of 801 °C. The HEMJ absorbed 750 W with a maximum armor surface temperature of 1411 °C and a fluid/solid interface temperature of 844 °C. For comparison, both the single HEMJ finger and the micro-jet array used 5-mm-thick tungsten armor. The ratio of maximum to average temperature and variations in the local heat transfer coefficient were lower for the micro-jet array compared to the HEMJ device. Although high heat flux testing is required to validate the results obtained in these simulations, the results provide important guidance in jet design and manifolding to increase heat removal while providing more even temperature distribution and minimizing non-uniformity in the gas flow and thermal stresses at the armor joint.
Sandia and Ultramet partnered to design and test refractory metal plasma-facing components and heat exchangers for advanced, high-temperature power conversion systems. These devices consisted of high-temperature helium-to-helium and lithium-to-helium heat exchangers that operate with high efficiency due to the porous foam inserts used in the gas stream, which promote turbulence and provide extended surface area for enhanced convection. Single- and multi-channel helium panels and the Li-He heat exchanger were fabricated from either pure molybdenum, TZM, or tungsten. The design was carried out through an Ultramet subcontractor. The flow path was carefully tailored to minimize the pressure drop while maximizing the heat transfer. The single- and multi-channel helium panels were tested at Sandia's PMTF using an electron beam system and the closed helium flow loop. In 2006, a single-channel tungsten tube was successfully tested to an average heat flux of 14 MW/m{sup 2} with a localized peak of 22 MW/m{sup 2} along the axial centerline at the outer radius. Under this CRADA, multiple square-channel molybdenum components were successfully tested to heat flux levels approaching 8.5 MW/m{sup 2}. The three multi-channel prototypes experienced mechanical failure due to issues related to the design of the large unsupported span of the heated faceplates in combination with prototype material and braze selection. The Li-He heat exchanger was both designed and partially tested at the PMTF for helium and lithium flow.
Several commercial computational fluid dynamics (CFD) codes now have the capability to analyze Eulerian two-phase flow using the Rohsenow nucleate boiling model. Analysis of boiling due to one-sided heating in plasma facing components (pfcs) is now receiving attention during the design of water-cooled first wall panels for ITER that may encounter heat fluxes as high as 5 MW/m2. Empirical thermalhydraulic design correlations developed for long fission reactor channels are not reliable when applied to pfcs because fully developed flow conditions seldom exist. Star-CCM+ is one of the commercial CFD codes that can model two-phase flows. Like others, it implements the RPI model for nucleate boiling, but it also seamlessly transitions to a volume-of-fluid model for film boiling. By benchmarking the results of our 3d models against recent experiments on critical heat flux for both smooth rectangular channels and hypervapotrons, we determined the six unique input parameters that accurately characterize the boiling physics for ITER flow conditions under a wide range of absorbed heat flux. We can now exploit this capability to predict the onset of critical heat flux in these components. In addition, the results clearly illustrate the production and transport of vapor and its effect on heat transfer in pfcs from nucleate boiling through transition to film boiling. This article describes the boiling physics implemented in CCM+ and compares the computational results to the benchmark experiments carried out independently in the United States and Russia. Temperature distributions agreed to within 10 °C for a wide range of heat fluxes from 3 MW/m2 to 10 MW/m2 and flow velocities from 1 m/s to 10 m/s in these devices. Although the analysis is incapable of capturing the stochastic nature of critical heat flux (i.e., time and location may depend on a local materials defect or turbulence phenomenon), it is highly reliable in determining the heat flux where boiling instabilities begin to dominate. Beyond this threshold, higher heat fluxes lead to the boiling crisis and eventual burnout. This predictive capability is essential in determining the critical heat flux margin for the design of complex 3d components.
Several commercial computational fluid dynamics (CFD) codes now have the capability to analyze Eulerian two-phase flow using the Rohsenow nucleate boiling model. Analysis of boiling due to one-sided heating in plasma facing components (pfcs) is now receiving attention during the design of water-cooled first wall panels for ITER that may encounter heat fluxes as high as 5 MW/m2. Empirical thermalhydraulic design correlations developed for long fission reactor channels are not reliable when applied to pfcs because fully developed flow conditions seldom exist. Star-CCM+ is one of the commercial CFD codes that can model two-phase flows. Like others, it implements the RPI model for nucleate boiling, but it also seamlessly transitions to a volume-of-fluid model for film boiling. By benchmarking the results of our 3d models against recent experiments on critical heat flux for both smooth rectangular channels and hypervapotrons, we determined the six unique input parameters that accurately characterize the boiling physics for ITER flow conditions under a wide range of absorbed heat flux. We can now exploit this capability to predict the onset of critical heat flux in these components. In addition, the results clearly illustrate the production and transport of vapor and its effect on heat transfer in pfcs from nucleate boiling through transition to film boiling. This article describes the boiling physics implemented in CCM+ and compares the computational results to the benchmark experiments carried out independently in the United States and Russia. Temperature distributions agreed to within 10 C for a wide range of heat fluxes from 3 MW/m2 to 10 MW/m2 and flow velocities from 1 m/s to 10 m/s in these devices. Although the analysis is incapable of capturing the stochastic nature of critical heat flux (i.e., time and location may depend on a local materials defect or turbulence phenomenon), it is highly reliable in determining the heat flux where boiling instabilities begin to dominate. Beyond this threshold, higher heat fluxes lead to the boiling crisis and eventual burnout. This predictive capability is essential in determining the critical heat flux margin for the design of complex 3d components.
Chemical vapor deposited (CVD) silicon carbide (SiC) has superior resistance to tritium permeation even after irradiation. Prior work has shown Ultrametfoam to be forgiving when bonded to substrates with large CTE differences. The technical objectives are: (1) Evaluate foams of vanadium, niobium and molybdenum metals and SiC for CTE mitigation between a dense SiC barrier and steel structure; (2) Thermostructural modeling of SiC TPB/Ultramet foam/ferritic steel architecture; (3) Evaluate deuterium permeation of chemical vapor deposited (CVD) SiC; (4) D testing involved construction of a new higher temperature (> 1000 C) permeation testing system and development of improved sealing techniques; (5) Fabricate prototype tube similar to that shown with dimensions of 7cm {theta} and 35cm long; and (6) Tritium and hermeticity testing of prototype tube.