Piyush Sabharwall

Diffusion-Welded Microchannel Heat Exchanger for Industrial Processes

The goal of next generation reactors is to increase energy efficiency in the production of electricity and provide high-temperature heat for industrial processes. The efficient transfer of energy for industrial applications depends on the ability to incorporate effective heat exchangers between the nuclear heat transport system and the industrial process. The need for efficiency, compactness, and safety challenge the boundaries of existing heat exchanger technology. Various studies have been performed in attempts to update the secondary heat exchanger that is downstream of the primary heat exchanger, mostly because its performance is strongly tied to the ability to employ more efficient industrial processes. Modern compact heat exchangers can provide high compactness, a measure of the ratio of surface area-to-volume of a heat exchange. The microchannel heat exchanger studied here is a plate-type, robust heat exchanger that combines compactness, low pressure drop, high effectiveness, and the ability to operate with a very large pressure differential between hot and cold sides. The plates are etched and thereafter joined by diffusion welding, resulting in extremely strong all-metal heat exchanger cores. After bonding, any number of core blocks can be welded together to provide the required flow capacity. This study explores the microchannel heat exchanger and draws conclusions about diffusion welding/bonding for joining heat exchanger plates, with both experimental and computational modeling, along with existing challenges and gaps. Also, presented is a thermal design method for determining overall design specifications for a microchannel printed circuit heat exchanger for both supercritical (24 MPa) and subcritical (17 MPa) Rankine power cycles.

Process Heat Exchanger Options for the Advanced High Temperature Reactor

The work reported herein is a significant intermediate step in reaching the final goal of commercial-scale deployment and usage of molten salt as the heat transport medium for process heat applications. The primary purpose of this study is to aid in the development and selection of the required heat exchanger for power production and process heat application, which would support large-scale deployment.

Natural Circulation and Linear Stability Analysis for Liquid-Metal Reactors with the Effect of Fluid Axial Conduction

The effect of fluid axial thermal conduction on one-dimensional liquid metal natural circulation and its linear stability was performed through nondimensional analysis, steady-state assessment, and linear perturbation evaluation. The Nyquist criterion and a root-search method were employed to find the linear stability boundary of both forward and backward circulations. The study provided a relatively complete analysis method for one-dimensional natural circulation problems with the consideration of fluid axial heat conduction. The results suggest that fluid axial heat conduction in a natural circulation loop should be considered only when the modified Peclet number is [approximately]1 or less, which is significantly smaller than the practical value of a lead liquid metal-cooled reactor.

THEORETICAL DESIGN OF THERMOSYPHON FOR PROCESS HEAT TRANSFER FROM NGNP TO HYDROGEN PLANT

The Next Generation Nuclear Plant (NGNP) will most likely produce electricity and process heat, with both being considered for hydrogen production. To capture nuclear process heat, and transport it to a distant industrial facility requires a high temperature system of heat exchangers, pumps and/or compressors. The heat transfer system is particularly challenging not only due to the elevated temperatures (up to ∼ 1300K) and industrial scale power transport (≥50 MW), but also due to a potentially large separation distance between the nuclear and industrial plants (100+m) dictated by safety and licensing mandates. The work reported here is the preliminary analysis of two-phase thermosyphon heat transfer performance with alkali metals. A thermosyphon is a device for transporting heat from one point to another with quite extraordinary properties. In contrast to single-phased forced convective heat transfer via ‘pumping a fluid’, a thermosyphon (also called a wickless heat pipe) transfers heat through the vaporization / condensing process. The condensate is further returned to the hot source by gravity, i.e. without any requirement of pumps or compressors. With this mode of heat transfer, the thermosyphon has the capability to transport heat at high rates over appreciable distances, virtually isothermally and without any requirement for external pumping devices. Two-phase heat transfer by a thermosyphon has the advantage of high enthalpy transport that includes the sensible heat of the liquid, the latent heat of vaporization, and vapor superheat. In contrast, single-phase forced convection transports only the sensible heat of the fluid. Additionally, vapor-phase velocities within a thermosyphon are much greater than single-phase liquid velocities within a forced convective loop. Thermosyphon performance can be limited by the sonic limit (choking) of vapor flow and/or by condensate entrainment. Proper thermosyphon requires analysis of both.Copyright

Process Heat Exchanger Options for Fluoride Salt High Temperature Reactor

The work reported herein is a significant intermediate step in reaching the final goal of commercial-scale deployment and usage of molten salt as the heat transport medium for process heat applications. The primary purpose of this study is to aid in the development and selection of the required heat exchanger for power production and process heat application, which would support large-scale deployment.

Modeling a Helical-coil Steam Generator in RELAP5-3D for the Next Generation Nuclear Plant

Options for the primary heat transport loop heat exchangers for the Next Generation Nuclear Plant are currently being evaluated. A helical-coil steam generator is one heat exchanger design under consideration. Safety is an integral part of the helical-coil steam generator evaluation. Transient analysis plays a key role in evaluation of the steam generators safety. Using RELAP5-3D to model the helical-coil steam generator, a loss of pressure in the primary side of the steam generator is simulated. This report details the development of the steam generator model, the loss of pressure transient, and the response of the steam generator primary and secondary systems to the loss of primary pressure. Back ground on High Temperature Gas-cooled reactors, steam generators, the Next Generation Nuclear Plant is provided to increase the readers understanding of the material presented.

Computational Thermodynamic Modeling of Hot Corrosion of Alloys Haynes 242 and HastelloyTM N for Molten Salt Service in Advanced High Temperature Reactors

Computational Thermodynamic Modeling of Hot Corrosion of Alloys Haynes 242 and HastelloyTM N for Molten Salt Service in Advanced High Temperature Reactors An evaluation of thermodynamic aspects of hot corrosion of the superalloys Haynes 242 and HastelloyTM N in the eutectic mixtures of KF and ZrF4 is carried out for development of Advanced High Temperature Reactor (AHTR). This work models the behavior of several superalloys, potential candidates for the AHTR, using computational thermodynamics tool (ThermoCalc), leading to the development of thermodynamic description of the molten salt eutectic mixtures, and on that basis, mechanistic prediction of hot corrosion.

Design of Liquid Metal Phase Change Heat Exchanger for Next-Generation Nuclear Plant Process Heat Application

The Next Generation Nuclear Plant will most likely produce electricity and its reactor heat will be further utilized for the production of hydrogen, oil recovery from tar sands and oil shales, and other process heat applications, that will further the nations pursuit of energy independence. An intermediate heat exchanger is required to transfer heat from the Next-Generation Nuclear Plant to the hydrogen plant (or other processes) in the most efficient way possible. Phase change heat exchangers are quite attractive in this regard, as they can transfer process heat more efficiently than for the single phase due to the advantage of high-enthalpy transport that includes the sensible heat of liquid, the latent heat of vaporization, and possible vapor superheat. This paper explores the overall heat transfer characteristics and pressure drop of the phase change heat exchanger with helium as the primary and sodium as the secondary heat exchanger coolant. For a two-phase boiling regime, the convective heat transfer coefficient is based on the concept of an additive, interacting mechanism of micro- and macroconvective heat transfer. In this analysis an improved design is proposed for given conditions, so as to obtain a lower overall pressure drop and a moderate/high overall heat transfer coefficient. The analysis presented in this paper will be useful as a guide for future experimental work for Next Generation Nuclear Plant process heat transfer.

Tritium Formation and Mitigation in High-Temperature Reactors

Tritium is a radiologically active isotope of hydrogen. It is formed in nuclear reactors by neutron absorption and ternary fission events and can subsequently escape into the environment. In order to prevent the tritium contamination of proposed reactor buildings and surrounding sites, this paper examines the root causes and potential solutions for the production of this radionuclide, including materials selection and inert gas sparging. A model is presented that can be used to predict permeation rates of hydrogen through metallic alloys at temperatures from 450–750°C. Results of the diffusion model are presented for one steadystate value of tritium production in the reactor.

Preliminary Design for Conventional and Compact Secondary Heat Exchanger in a Molten Salt Reactor

In this study, the heat transfer coolant utilized in the heat exchanger is a molten salt, which transfers thermal energy to water (steam) for power production by a supercritical Rankine (25MPa) or subcritical Rankine (17MPa) cycle. Molten salts are excellent coolants, with 25% higher volumetric heat capacity than pressurized water, and nearly five times that of liquid sodium. The greater heat capacity of molten salts results in more compact components like pumps and heat exchangers. However, the use of a molten salt provides potential materials compatibility issues. After studying a variety of individual molten salt mixtures, chlorides and fluorides have been given the most serious consideration because of their heat transport and transfer characteristics.In this study thermal designs of conventional (shell and tube), and compact (printed circuit) heat exchangers are carried out and compared for a given thermal duty. There are a couple of main issues that need to be addressed before this technology could be commercialized. The main issue is with the material compatibility of molten salts (especially fluoride salts) and secondarily, with the pressure difference across the heat exchanger. The heat exchanger’s primary side pressure is nearly atmospheric and the secondary side (power production) is pressurized to about 25MPa for supercritical cycle and 17MPa for subcritical cycle. Further in the analysis, the comparison of both the cycles will be carried out with recommendations.© 2012 ASME