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Thermal-Hydraulic Experimental Facilities forAdvanced Reactor Development at INL

Piyush Sabharwall, Ph.D.Adv. Heat Transport LeadNuclear Staff Researcher, Systems Integration DepartmentNuclear Science and Technology DivisionIdaho National Laboratory

July 13, 2017, NSUF/GAIN Nuclear Thermal-Hydraulics Workshop, Idaho Falls, ID

Contents• OBJECTIVE

• EXPERIMENTAL CAPABILITIES

– ARTIST (Design-Phase)

• Salt Preparation and Purification Setup

• Molten Salt Transfer Experiment

– MISTER

– SPECTR

– MIR

• CONCLUSIONS

Advanced Reactor Technology Integral System Test (ARTIST) Facility

High-temperature multi-fluid, multi-loop test facility to support thermal hydraulic, materials, and thermal energy storage research for nuclear and nuclear-hybrid applications is being developed.

O’Brien, J. E., Sabharwall, P., and Yoon, S., and Housley, G. K., “Strategic Need for a Multi-Purpose Thermal Hydraulic Loop for Support of Advanced Reactor Technologies,” INL/EXT-14-33300, October, 2014.

Sabharwall, P., O’Brien, J.E., and Yoon, S.J., “Experimental facility for development of high-temperature reactor technology: instrumentation needs and challenges,” EPJ Nuclear Science and Technology, 2015

ARTIST Facility Engineering and Research Objectives• Performance evaluation of candidate compact heat exchangers such as printed

circuit heat exchangers (PCHEs) at prototypical operating conditions for IHX and SHX applications

• Characterization of flow and heat transfer issues related to core thermal hydraulics in advanced helium-cooled and salt-cooled reactors, and evaluation of corrosion behavior of new cladding materials and accident-tolerant fuels for LWRs at prototypical conditions

• Provide V&V data for new TH codes • Demonstration of advanced instrumentation at prototypical conditions• Integration with co-located energy systems for characterization of dynamic

behavior

• INL has initiated development of a new multi-fluid multi-loop thermal hydraulic test facility at INL, and associated technology development

• Based on its relevance to advanced reactor systems, the new test facility has been named the Advanced Reactor Technology Integral System Test (ARTIST) facility

New INL Experimental Capability

3-D CAD model of the ARTIST Facility

O’Brien, J.E., Sabharwall, P., Yoon S.J., and Housley, G.K., “Strategic Need for Multi-Purpose Thermal Hydraulic Loop for Support of Advanced Reactor Technologies,” External Report, INL/EXT-14-33300, Idaho National Laboratory, Idaho, September, 2014.

Process flow diagram for the ARTIST test facility

High Temperature Test Section

Intermediate-T Test Section

He

Helium Circulator

Helium Supply and Pressurizer

He-He Recuperator

(60 kW)

Chiller

High Temperature Gas Heater

(60 kW)

Flow Meter (11300 SLPM)

Cooling Water

IHX(55 kW)

Salt Storage/ Drain Tank and

Circulation Pump

Helium Loop Liquid Salt Loop

Thermal Energy Storage

(275 kW hr)

Flow Meter(1 kg/s)

SHX/Steam Generator

(55 kW)

Auxiliary Heater (75 kW)

Water Storage and Deaeration

Tank

Chiller

Flow Meter(16.5 LPM)

Steam/Water Loop

Cooling Water

Process Feed

Process Return

Process Feed

Deae

ratio

n ve

nt

Deae

ratio

n ve

nt

Circulation Pump

Process Return

High Temperature Test Section

High

Tem

pera

ture

Te

st S

ectio

n

Heat Tracing

PT

T

T P

T

TT

P

T P

TP

Deae

ratio

n ve

nt

Vacuum Pump

T

T

T

Water Chemistry Control

Salt Chemistry Control

Vacuum Pump

Auxiliary heater

N2

Fill line

Vent

Accumulator

15 MPa

∆P ∆P

TP

Inert cover gas

7 MPa, 750°C 0.2 MPa, 480°C15 MPa,

325°C

6.8 MPa, 450°C

0.19

MPa

, 43

0°C

15 MPa, 50°C

7.1 MPa, 50°C

0.2 MPa, 430°C

15 MPa, 50°C

6.5 MPa, 100°C

TP

7.0 M

Pa,

400°

C

0.2 M

Pa,

430°

C

15 MPa, 275°C

15 MPa, 50°C

H2O-H2O recuperator/

condenser (200 kW)

∆P ∆P

15 MPa, 117°C

T

Fil l line

P

T∆P ∆P

TT

TT

T

TP

T

T P

T

T

T

∆P ∆P

∆P

∆P ∆P

∆P

∆P

6.4 M

Pa,

31°C

High-Pressure Water Flow Loop

• Designed to operate at PWR conditions

• Can support both forced and natural circulation modes

• Will be deployed at the INL Energy Systems Laboratory during FY17

• Co-located with various hybrid energy systems

• Currently in final design phaseH 2

O-H 2

O Rec

upera

tion /

co

nden

ser H

PW-CO

ND-01

High-pressure PumpHPW-PMP-02

N2

Circulation PumpHPW-PMP-01

Self-venting Regulator

N2-REG-0115 MPa

Accumulator TankHPW-TK-02

Flowmeter (0-20 gpm)HPW-FM-01

T

P

Chiller(Located Outside)

CWS-CH-01

Deaeration Vent

HPW-HV-08

HPW-CK-01

Auxiliary HeaterHPW-AH-01

HPW

-MOV

-06

Process Feed

2" HPW

Process Return

2" HPW

HPW-MOV-05

HPW-MOV-03

∆P ∆P

HPW-MOV-07

HPW

-MOV

-02

∆P

Heat

Excha

nger

and

Coole

rHP

W-H

X-01

Primary Water Storage TankHPW-TK-01

IW Water Fill

HPW-PRV-01

HPW-TC-08

Nitrogen Pressurizer Gas

N2-TK-01

N2-PRV-01

Vent

N2-H

V-01

HPW-HV-09

HPW-HV-05HPW-HV-04

HPW-PT-01

HPW-TC-01

HPW-PT-02

HPW-TC-02 T

P

HPW-TC-07

HPW-PT-03

HPW-TC-03

HPW-PT-04

HPW-TC-04

T

P HPW-PT-05

HPW-TC-05CWS-FM-01

CWS-TC-02

CWS-TC-01

2 ½" CWR

2 ½" CWR

FC Loop Pressure Relief

T

¼-in N2 line

¼-in tubing ¼-in tubing

Note: HPW-SV-01 and HPW-SV-02 should be automatically closed in the event of a PRV trip

T

P

T

P

Open vent to outside (no valves)

NC loop Pressure Relief

T

T

HPW-PRV-03

HPW-PRV-02

PRV control signal

Sample Port

NC

FCNC

FC

Signal to accumulator outlet solonoid

Signa

l from

PRVs

HPW-HV-10

HPW-SV-02

HPW-HV-02

DI-HV-01

HPW-SV-01

HPW-SV-03

HPW-MOV-01

HPW

-MOV

-04

HPW

-MOV

-10

HPW-HV-06

HPW-MOV-11

HPW-HV-07Conductivity

SensorHPW-CN-01

Dissolved Oxygen Sensor

HPW-DO-01O

C

HPW-CN-02

HPW-DO-02 O

C

Rm D109

DI Water Storage

TankDI-TK-01

Drain Lift StationHPW-DI-02

Alarm StationHPW-ARM-01

HPW-HV-03

DI-HV

-05

DI-HV-04

Loop LowPoint Drain(s)

Building Sewer Room D109

SW-HV-01

DI-PMP-02

DI-PMP-01

DI-HV-02

DI-HV-03

DI SystemDI System

DI System

DI SystemHPW-DI-01

DI Water System Drain Line

HPW-CK-02

Drain

HPW-HV-01Sample Port

½ -in tubing½ -in tubing

Valve Label Color LegendBlack: check valvesGreen: non-main loop valves (small lines)Red: high-T 2-in ball valves, motor-operatedLight blue: low-T 2-in ball valves, motor-operatedDark blue: pressure relief valves (PRV)Purple: solonoid valves

HPW-DP-01

HPW

-DP-0

3

HPW

-DP-0

4

HPW-DP-05

DI-CK-01spare

nozzles

level indicator

HPW-LI-02

level indicator

HPW-LI-01

HPW-HV-11

Sample Port

HPW

-MOV

-09

HPW-MOV-08

High T

empe

rature

Test

Secti

on HW

P-HTS

-01

∆P

∆P

Note:

pipe

secti

on w

ith

NC flo

w me

ter an

d or

ifice w

ill be

remo

ved

for FC

flow

N2-HV-02

T

Pressure GaugeN2-PT-01

HPW-PRV-04

NC Orifice PlateHPW-IO-01

NC FlowmeterHPW-FM-02

HPW

-DP-0

2

HPW-PT-06

HPW-TC-06 T

P

General Loop Operating Conditions

Specific Research topics: Water Loop High-Temperature Test Section

• prototypic evaluation of new cladding materials accident-tolerant fuel materials• characterization of thermal, chemical, and structural properties of candidate

advanced fuel cladding materials and designs under various simulated flow and internal heating conditions to mimic operational reactor conditions prior to in-reactor testing

• evaluate performance of advanced heat exchanger designs such as PCHEs for high-temperature, high-pressure heat transfer with intermediate fluids such as molten salts

• flow-induced vibration of simulated sodium-cooled reactor fuel rod bundles• reactor-safety-relevant natural circulation studies• provide dynamic thermal energy source for co-located systems including HTE

and thermal energy storage systems

Supplemental Heat~315 C (600 F)

ARTIST PWR Flow Loop~325 C (600 F) Heat Source

INL 25kW High TemperatureElectrolysis Test Station

Chiller (heat sink)

RTDS Supervisory Control(issues commands based

on monitored grid conditions)

Computer controlled molten salt thermal energy storage

Overall DETAIL Facility Display and Data Acquisition

RTDS Data & CommandsThermal Supervisory Data & CommandsHeat FlowCoolant FlowElectrical Power Flow

Turnkey 25-100 kW High TemperatureElectrolysis Demonstration Infrastructure

Credit: Dr. Carl StootsCarl.Stoots@inl.gov

Thermal Supervisory Control(balances heat flows)

Dynamic Energy Transport and Integration Laboratory (DETAIL)

Salt Preparation and Purification Setup&

Molten Salt Transfer Experiment

Molten Salt Transfer Experiment

primary test vesselsalt storage vessel

500 sccm

heated fluid transfer line

He

P

T

molten salt line heater

coolingwater in

T

T

T

T T

tolaboratoryexhaust (4"stack)

filter

doll kiln

10psig

75 psigfloworifice

1/2"

1/4"spareinstrumentationpenetration(capped)

topurificationexperiment

T T

T

T

T

Hepurge linetopurificationexperiment

control

over-Temp

control

over-Temp

over-Temp

tube1/8"fromvessel bottom tube3/8"from

vessel bottom

over-Temp

controlcontrol

T

coolingwaterout10psig

T1/2"A

B

C

D

He-1He-2

He-3

R-3

• Liquid salts will be transferred from one pot to another to validate high temperature trace heating and flow measurement methods

• Primary system components include an inert gas supply, mass flow controller, pressure relief valve, pressure transducer, a water-cooled furnace assembly, a doll kiln, a primary test vessel, fluid storage vessel, a filter, and a heat-traced fluid transfer line

Salt Preparation and Purification to support ARTIST

Glove box for molten salt preparation and salt transfer/flow experiment.

Salt Preparation, property measurement, and flow experiment

Nickel (alloy 201) vessels for salt purification and transfer experiments

FLiNaK ingot top surfaceFLiNaK ingot and glassy carbon crucible

a) unpurified b) after one purification run

H2 He He+HF

to laboratoryexhaust (processgas with HF)

outlet gassensor

glovebox boundary

salt transfer guide tube(capped during purification)

ventilated gassafety cabinet

Psolonoidvalve

glovebox pressurerelief (0.18 psi)

floworifice

He purge

cooling waterin/out

T

T

ArorN2

Ar (or N2) outlet togas safety cabinet andlaboratory exhaust

Ventilation Air outlet tolaboratory exhaust (6 in)

Ar or N2

75 psig

H2+He

He/HF

He purge

H2

75 psig

50 SLPM

500 sccm

500 sccm

100 sccm

Antechamber

solonoidvalve

10 psig

to transferexperiment

0.18 psi

75 psig

75 psig

Ts

T

control

over-Temp

vent to room

T

Ts

Ts

H2 vent

T

850 psig

10 psig

Ar-2

Ar-3

Ar-4

HeHF-1

H2-1

He-1

He-2He-3 He-4

P-1

P-2

P-3

R-1 R-2 R-3R-4

R-5

H2-2

GasManifold

Salt Preparation and Purification (Hydrofluorination HF/H2/He)

• Gain experience with safe methods of fluoride salt mixture handling, preparation, and purification• Characterize salt impurities • Measure eutectic salt mixture thermophysical properties such as thermal conductivity and specific heat

Expected Outcomes

PCHE CFD Analysis and V&V

δ

Hot fluid side

Cold fluid side

Solid bodyH

W

D

0

50

100

150

200

250

300

0 300 600 900 1200 1500 1800 2100

f app·R

e

Re

lR/Dh = 4.09lR/Dh = 4.91lR/Dh = 6.55lR/Dh = 8.18lR/Dh = 12.3lR/Dh = 16.4lR/Dh = 32.7

lR/DhlR/DhlR/DhlR/DhlR/DhlR/DhlR/Dh

CFD V&V

Correlation Development

Yoon, S., O’Brien, J.E., Chen, M., Sabharwall, P., and Sun, X., “Development and Validation of Nusselt Number and Friction Factor Correlations for Laminar flow in Semi-circular Zigzag Channel of Printed Circuit Heat Exchanger,” Applied Thermal Engineering, 2017

Component Test Facilities (Test Rigs)

Mixed Stream Test Rig (MISTER): Corrosion Testing of Small Specimens in Multiple/varied Gas Streams

Conceptual drawing of MISTER

• Provides high pressure/temperature gas mixtures to small test article

• Furnace temperatures up to 1000°C• Completed first test of HTSE alloys

Loading specimen into MISTER using quartz boats

• Completed start-up in January 2011 (L2 milestone)• 500 hour test of high temperature electrolysis “balance

of plant” specimens completed• Specimens undergoing analysis• Minor upgrades, additions to spares, etc., completed

in April 2011Kevin Dewall*

Small Pressure Cycling Test Rig (SPECTR): Mechanical Testing of Small (up to 8 in3 HX sections)

• Provides high pressure gas to primary and secondary of test article

• Furnace temperatures up to 1000°C

• Operational summer 2011 (L2 milestones)

• Capable of SOEC pressurized testing for TRL 5

SPECTR Purpose• Proof test diffusion bonded IHX

to draft ASME code case procedure

• Demonstrate IHX performance for cyclic pressures

• Used to answer several DDNs

SPECTR furnace fabrication at AVSBill Landman*

SPECTR system viewed from inside Bay W-3 of IEDF

Test article gas supply and exhaust system

Landman, W.H., “SPECTR System Operational Test Report.,” INL/EXT-11-22903, August 2011.

Main Display Screen for Control System

Matched Index of Refraction Flow Facility

(https://mir.inl.gov)

Stoots, C., S. Becker, K. Condie, F. Durst, and D. McEligot, 2001, “A Large Scale Matched Index of Refraction Flow Facility for LDA Studies Around Complex Geometries,” Exp. in Fluids, Vol. 30, pp. 391–398.

Conder, T.E., “Particle Image Velocimetry Measurements in a Representative Gas Cooled Prismatic Reactor Core Model For the Estimation of ByPass Flow,” Doctoral Dissertation, December 2012.

MIR Experiment Facility• INL has a variety of 21st century (i.e. state of the art) flow facilities and

measurement techniques applicable to code/model for verification and validation

Match Index of Refraction Facility

Particle Image Velocimetry

• Bypass Flow Experiment (CFD under predicted the flow through the gap)– complex flow geometry– experimental results needed for CFD analysis

• To measure entropy generation rate within the bypass transitional region of the boundary layer ( ‘bypass’ is bypassing the Tollmein Schlichting waves of transition in quite laminar flow by introducing high turbulence in the freestream away from the plate)

Technical Specifications

Characteristic Specification

Test Section Cross Section

0.61 m × 0.61 m (24 in × 24 in)

Test Section Length 2.44 M (8 FT)

Contraction Ratio 4:1

Working Fluid Drakeol #5 Light Mineral Oil

Index-Matching Temperature (ºC)

Laser Wavelength Dependent

Mineral Oil Density Matching Temperature Dependent

Refractive Index of Mineral Oil and Fused Quartz

Matching Temperature Dependent

Mineral Oil Kinematic Viscosity

Matching Temperature Dependent

Temperature Control External

Maximum Inlet Velocity 1.9 m/s (6.2 ft/s)Inlet Turbulence Intensity 0.5%–15%

Data from old experiments

Conduct new experiments

Experimental guided models for validation

Assess new safety measures: Passive decay heat removal Natural circulation

Uncertainty quantification

Develop new instrumentation techniques (if required)

Demonstrate new reactor concept features and improved correlations

Conclusions• Exciting challenges ahead!

• Innovative ideas needed to drive down costs.

• Successful demonstration are needed to gain utility, regulator, and public confidence.

Thanks…!

Piyush Sabharwall Idaho National LaboratoryPiyush.Sabharwall@inl.gov (208) 526-6494

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