Publications

Multiphysics and analytical calculations were conducted for a heat exchanger with passive, natural circulation flow. A glycol/water working fluid convects the heat to a dimpled heat exchanger shell, which subsequently transfers the heat to the soil, which acts as the ultimate heat sink. Because the system is fully-passive, it is not subject to the expenses, maintenance, and mechanical breakdowns associated with moving parts. Density, heat capacity, and thermal conductivity material properties were measured for various soil samples, and subsequently included as input for the soil heat conduction model. The soil model was coupled to a computational fluid dynamics (CFD) heat exchanger model that included the dynamic Smagorinsky large eddy simulation and k- omega turbulence models. The analysis showed that the fluid dynamics and heat transfer models worked properly, albeit at a slow pace. Nevertheless, the coupled CFD/heat conduction simulation ran long enough to determine a key parameter—the amount of heat conducted from the heat exchanger to the ground. This unique performance value, along with experimental data, was used as input for stand-alone, fast-running CFD models, as well as boundaries to obtain solutions to partial differential equations for soil heat conduction.

Exterior solar glaze was added to a 3 foot x 3 foot x 3 foot aluminum solar collector that had six triangular dimpled fins for enhanced heat transfer. The interior vertical wall on the south side was also dimpled. The solar glaze was added to compare its solar collection performance with unglazed solar collector experiments conducted at Sandia in 2021. The east, west, front, and top sides of the solar collector were encased with solar glaze glass. Because the solar incident heat on the north and bottom sides was minimal, they were insulated to retain the heat that was collected by the other four sides. The advantages of the solar glaze include the entrapment of more solar heat, as well as insulation from the wind. The disadvantages are that it increases the cost of the solar collector and has fragile structural properties when compared to the aluminum walls. Nevertheless, prior to conducting experiments with the glazed solar collector, it was not clear if the benefits outweighed the disadvantages. These issues are addressed herein, with the conclusion that the additional amount of heat collected by the glaze justifies the additional cost. The solar collector glaze design, experimental data, and costs and benefits are documented in this report.

An analytical expression for turbulent kinematic viscosity (vt), based solely on the hydraulic Reynolds number (Re), was derived and evaluated. The analytical expression is valid for the fast estimation of vt for internal, isotropic, fully developed flows. The expression was compared with experimental and simulation data for air, water, and liquid sodium, and was shown to provide reasonable values for 2100 ≤ Re ≤ 3.6 × 106 and Prandtl number (Pr) range of 0.0107 ≤ Pr ≤ 5.65. In addition, new expressions suitable for the central portion of internal flows, away from the wall, were derived for the turbulent Reynolds number (ReT), showing its relationship to Re, as well as to the ratio of vt and the molecular kinematic viscosity (v).

A 3 foot x 3 foot x 3 foot aluminum solar collector was manufactured using computer numerical control. The interior of the device included six triangular dimpled fins for enhanced heat transfer. The interior vertical wall on the south side was also dimpled. The solar collector working fluid was based on water, and the collector consisted solely of passive heat transfer mechanisms (no moving parts), making it ideal for off-the-grid and rural applications. Two types of heat transfer experiments were conducted. One experiment had external flat heaters attached on the top and the front side, while the other four sides were insulated. Except for the bottom surface, the second experiment had all its exterior surfaces sprayed with black solar paint to collect as much solar heat as possible. Temperature data as a function of time was collected using 14 thermocouples spread strategically throughout the solar collector. In addition, computational fluid dynamics (CFD) simulations were conducted using the dynamic Smagorinsky large eddy simulation turbulence model. The first simulation considered that both the top and front surfaces were exposed to a fixed temperature of 313.7 K (105 °F), while the remaining four surfaces were insulated. For the second simulation, all conditions were the same, except that the temperature for both heated surfaces was raised to 350 K (170.3 °F). The two temperatures are expected to bound the solar collector operational temperature during the late- Spring, Summer, and early-Fall months. The solar collector design, experimental data, CFD output, and a discussion of five manufacturing approaches and costs are documented in this report.

An exceptional set of newly-discovered advanced superalloys known as refractory high-entropy alloys (RHEAs) can provide near-term solutions for wear, erosion, corrosion, high-temperature strength, creep, and radiation issues associated with supercritical carbon dioxide (sCO2) Brayton Cycles and advanced nuclear reactors. In particular, these superalloys can significantly extend their durability, reliability, and thermal efficiency, thereby making them more cost-competitive, safer, and reliable. For this project, it was endeavored to manufacture and test certain RHEAs, to solve technical issues impacting the Brayton Cycle and advanced nuclear reactors. This was achieved by leveraging Sandia’s patents, technical advances, and previous experience working with RHEAs. Herein, three RHEA manufacturing methods were applied: laser engineered net shaping, spark plasma sintering, and spray coating. Two promising RHEAs were selected, HfNbTaZr and MoNbTaVW. To demonstrate their performance, erosion, structural, radiation, and hightemperature experiments were conducted on the RHEAs, stainless steel (SS) 316 L, SS 1020, and Inconel 718 test coupons, as well as bench-top components. The experimental data is presented, analyzed, and confirms the superior performance of the HfNbTaZr and MoNbTaVW RHEAs vs. SS 316 L, SS 1020, and Inconel 718. In addition, to gain more insights for larger-scale RHEA applications, the erosion and structural capabilities for the two RHEAs were simulated and compared with the experimental data. The experimental data confirm the superior performance of the HfNbTaZr and MoNbTaVW RHEAs vs. SS and Inconel. Most importantly, the erosion and the coating material experimental data show that erosion in sCO2 Brayton Cycles can be eliminated completely if RHEAs are used. The experimental suite and validations confirm that HfNbTaZr is suitable for harsh environments that do not include nuclear radiation, while MoNbTaVW is suitable for harsh environments that include radiation.

An open-literature search was conducted to consider the current status of the additive manufacturing (AM) industry with respect to metal alloys and refractory high entropy alloys (RHEAs). Key areas of interest include methodologies and applications that are suitable for the nuclear and aerospace industries, as well as other industrial applications. We investigated various promising 3D metal technologies, with emphasis on cost, operation, throughput, maintenance, and output volume size. In addition, technical issues and the current status of the metal printing market are summarized. The project scope also included the manufacturing of open-literature RHEA test coupons at Sandia's laser engineered net shape (LENS) machine.

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SNL has a combination of experimental facilities, nuclear engineering, nuclear security, severe nuclear accidents, and nuclear safeguards expertise that can enable significant progress towards molten salts and fuels for Molten Salt Reactors (MSRs). The following areas and opportunities are discussed in more detail in this white paper.

Smart grids are a crucial component for enabling the nation’s future energy needs, as part of a modernization effort led by the Department of Energy. Smart grids and smart microgrids are being considered in niche applications, and as part of a comprehensive energy strategy to help manage the nation’s growing energy demands, for critical infrastructures, military installations, small rural communities, and large populations with limited water supplies. As part of a far-reaching strategic initiative, Sandia National Laboratories (SNL) presents herein a unique, three-pronged approach to integrate small modular reactors (SMRs) into microgrids, with the goal of providing economically-competitive, reliable, and secure energy to meet the nation’s needs. SNL’s triad methodology involves an innovative blend of smart microgrid technology, high performance computing (HPC), and advanced manufacturing (AM). In this report, Sandia’s current capabilities in those areas are summarized, as well as paths forward that will enable DOE to achieve its energy goals. In the area of smart grid/microgrid technology, Sandia’s current computational capabilities can model the entire grid, including temporal aspects and cyber security issues. Our tools include system development, integration, testing and evaluation, monitoring, and sustainment.

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While arc-faults are rare in electrical installations, many documented events have led to fires that resulted in significant damage to energy-generation, commercial and residential systems, as well as surrounding structures, in both the United States and abroad. Arc-plasma discharges arise over time due to a variety of reliability issues related to cable material degradation, electrical and mechanical stresses or acute conductive wiring dislocations. These may lead to discontinuity between energized conductors, facilitating arcing events and fires. Arc-flash events rapidly release significant energy in a localized volume, where the electric arc experiences a reduction in resistance. This facilitates a reduction in electrical resistance as the arc temperature and pressure can increase rapidly. Strong pressure waves, electromagnetic interference (EMI), and intense light from an arc pose a threat to electrical worker safety and system equipment. This arc-fault primer provides basic fundamental insight into arc-fault plasma discharges, and an overview of direct current (DC) and alternating current (AC) arc-fault phenomena. This primer also covers pressure waves and EMI arc-fault hazard analyses related to incident energy prediction and potential damage analysis. Mitigation strategies are also discussed related to engineering design and employment of protective devices including arc-fault circuit interrupters (AFCIs). Best practices related to worker safety are also covered, especially as they pertain to electrical codes and standards, particularly Institute of Electrical and Electronics Engineers (IEEE) 1584 and National Fire Protection Agency (NFPA) 70E. Throughout the primer various modelling and test capabilities at Sandia National Laboratories are also covered, especially as they relate to novel methods of arc-fault/arc-flash characterization and mitigation approaches. Herein, this work describes methods for producing and characterizing controlled, sustained arcs at atmospheric pressures as well as methods for mitigation with novel materials.

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Safety basis analysts throughout the U.S. Department of Energy (DOE) complex rely heavily on the information provided in the DOE Handbook, DOE - HDBK - 3010, Airborne Release Fractions/Rates and Respirable Fractions for Nonreactor Nuclear Facilities, to determine radionuclide source terms. In calculating source terms, analysts tend to use the DOE Handbook's bounding values on airborne release fractions (ARFs) and respirable fractions (RFs) for various categories of insults (representing potential accident release categories). This is typically due to both time constraints and the avoidance of regulatory critique. Unfortunately, these bounding ARFs/RFs represent extremely conservative values. Moreover, they were derived from very limited small-scale bench/laboratory experiments and/or from engineered judgment. Thus, the basis for the data may not be representative of the actual unique accident conditions and configurations being evaluated. The goal of this research is to develop a more accurate and defensible method to determine bounding values for the DOE Handbook using state-of-art multi-physics-based computer codes. This enables us to better understand the fundamental physics and phenomena associated with the types of accidents in the handbook. In this year, this research included improvements of the high-fidelity codes to model particle resuspension and multi-component evaporation for fire scenarios. We also began to model ceramic fragmentation experiments, and to reanalyze the liquid fire and powder release experiments that were done last year. The results show that the added physics better describes the fragmentation phenomena. Thus, this work provides a low-cost method to establish physics-justified safety bounds by taking into account specific geometries and conditions that may not have been previously measured and/or are too costly to perform.

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Recent advances in the literature and at SNL indicate the strong potential for passive, specialized surfaces to significantly enhance power production output. Our exploratory computational and experimental research indicates that fractal and swirl surfaces can help enable waterless-power production by increasing the amount of heat transfer and turbulence, when compared with conventional surfaces. Small modular reactors, advanced reactors, and non-nuclear plants (e.g., solar and coal) are ideally suited for sCO2 coolant loops. The sCO2 loop converts the thermal heat into electricity, while the specialized surfaces passively and securely reject the waste process heat in an environmentally benign manner. The resultant, integrated energy systems are highly suitable for small grids, rural areas, and arid regions.

Sandia National Laboratories and General Atomics are pleased to respond to the Advanced Research Projects Agency-Energy (ARPA-e)’s request for information on innovative developments that may overcome various current reactor-technology limitations. The RFI is particularly interested in innovations that enable ultra-safe and secure modular nuclear energy systems. Our response addresses the specific features for reactor designs called out in the RFI, including a brief assessment of the current state of the technologies that would enable each feature and the methods by which they could be best incorporated into a reactor design.

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