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3D Conjugate Heat Transfer Analysis of the Next Generation Inner Reflector Plug for the Spallation Neutron Source Ashraf Abdou Oak Ridge National Laboratory , Oak Ridge TN, USA March 18-20, 2013 STAR Global Conference 2013 Orlando, Florida,

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3D Conjugate Heat Transfer Analysis of the Next Generation Inner Reflector Plug for the Spallation Neutron Source

Ashraf Abdou

Oak Ridge National Laboratory , Oak Ridge TN, USA STAR Global Conference 2013 Orlando, Florida, USA March 18-20, 2013

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2 Managed by UT-Battelle for the U.S. Department of Energy

STAR Global Conference 2013

The Spallation Neutron Source at ORNL

LIN LINAC

Accelerate the beam to 1 GeV

Accumula Accumulator tor Ring Ring

Compress 1 msec long pulse to 700 nsec

Target building & neutron instruments

Proton beam pulses to Target at 60 Hz

Central Laboratory & Office Complex

Center for Nanophase Material Science

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STAR Global Conference 2013

SNS Instruments Cover a Wide Range of Science

18 neutron beam lines some accommodate more that 1 instrument

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STAR Global Conference 2013

Proton Beam

Liquid Mercury Target Module

Reflector Plugs

SNS Target Systems Core Region

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STAR Global Conference 2013

SNS Target Systems Core Region

Inner Reflector Plug Outer Reflector Plug Core Vessel Proton Beam Window Neutron Beam Lines Target Moderators (4) Proton Beam

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STAR Global Conference 2013

CFD Simulations of SNS Systems

  • SNS Systems are built in PRO-E Creo parametrics
  • Neutronics Analysis

– Codes: MCNPX and other codes – Volumetric power deposition in Liquids and solids

  • Thermal-Hydraulic Analysis

– Codes: STAR-CCM+V7, ANSYS-CFX, Fluent V14.5 and ICEM-CFD – Grids: conformal Hexahedral and Polyhedral – Conjugate Heat Transfer Analysis – Two-Phase Flow for Gas layers and gas bubbles – Fluids: Liquid mercury, heavy and light water, supercritical hydrogen and gases

  • Stress Analysis

– Codes: ABAQUS and ANSYS

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STAR Global Conference 2013

2nd Generation Inner Reflector Plug (IRP)

Proton

  • ton

Beam Beam Tar arget get Middle Reflector Plug (MRP)

Lower IRP

SS, Be, Al, and Cd 31.75” OD X 73” tall, 7000 lbs.

Intermediate IRP

Stainless Steel 31.75” OD X 22” tall, 4095 lbs.

Be Be Existing IRP

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STAR Global Conference 2013

2nd Generation MRP Design

Outlet Inlet 80 gpm 40 C

Aluminum Can 2 SS inserts

Inlet side Outlet side Proton Beam

0.25 inch 0.25 inch Hole diameters in the inlet side is 0.5 inch Hole diameters in the outlet side is 0.375 inch

Hea Heavy vy Water ter

Water Plenum

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STAR Global Conference 2013

2nd Generation IRP Design

Ber Beryll yllium ium Al Aluminu uminum

Light W Light Water ter

Pr Pre-Moderators

Hea Heavy vy Water ter

40 gpm 40 C 40 gpm 40 C Outlet 15 gpm each 40 C 15.85 gpm 40 C 15.85 gpm 40 C

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STAR Global Conference 2013

Volume

  • lumetri

tric c Hea Heat t Gene Generati tion

  • n (

(W/m W/m3) ) in A in Aluminum luminum at 2 t 2 MW Be MW Beam am P Power er IRP MRP

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Water ter/A /AL L inter interface ace

Temperature Contours at Water/SS, Water/AL and Water tubes/SS interfaces

Water/SS interface SS SS/W /Water t ter tube ubes interf s interface ace

SS Insert1 SS Insert2

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SNS Mercury Target Module

Mercury vessel surrounded by a water-cooled shroud

Bulk mercury flow Water-cooled Shroud Mercury Target Vessel

Proton Beam

quasi-stagnation region at the center of the window

Re = 0.7×106 12 L/s

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Conjugate Heat Transfer of SNS Liquid Mercury (1.54 MW Beam Power)

Deposited Power In SS: 63.8 kW

Deposited Power in HG: 777.46 kW

Constant Volume Heating Process Leads to Large Pressure Pulse in Liquid Mercury

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STAR Global Conference 2013

Conjugate Heat Transfer of SNS Liquid Mercury

  • K- SST Mentor turbulence model
  • Turbulent Prantdl number
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STAR Global Conference 2013

Ca Cavit vitation tion Dama Damage ge Er Erosion

  • sion of
  • f the T

the Tar arget get Module Module Tar arget # get # 8 is 8 is running unning at t about 1 M bout 1 MW W Beam Beam Power er

Specimen diameter: 60 mm Original thickness: 3 mm

Off-center, bulk Hg surface Center, bulk Hg surface

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Textured SNS window: 24 L/s

Conical pits Stagnation Zone

Vertical V Grooves Gas Injection: 500 sccm per port Vertical V Grooves

Horizontal V Grooves Horizontal V Grooves Horizontal V Grooves Horizontal V Grooves

Horizontal V Grooves Horizontal V Grooves

Sweeping Mercury Flow Sweeping Mercury Flow

Close up view

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Experiments in liquid Mercury: Video of Textured Gas Wall at the window (24L/s)

Conical Pits Vertical Grooves Vertical Grooves

He gas injection at 500 sccm each

Horizontal Feeder Grooves

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Time Averaged Helium VF Contours

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Animation of Gas Volume Fraction contours (24 L/s)

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Summar Summary

  • STAR-CCM+ is being used at SNS for :

– conjugate heat transfer with water in complex geometries – conjugate heat transfer with liquid metal in separated flows – Two-Phase flow for developing gas wall layer over textured wall

  • The simulations provide guidance for the experiments, and may be used as a diagnostic

tool for probing inside the opaque mercury. CFD is thus demonstrated to be a promising method for optimization of a gas wall to mitigate cavitation erosion of the SNS target. Comme Comment nts: s:

  • Communication between PRO-E Creo and STAR-CCM+ CAD thru 3D CAD Exchange to

prepare the models for conformal polyhedral grid

  • Interface Imprinter in STAR-CCM+ CAD with importing Para solid and IGES files
  • Parametric studies: Writing the solution settings, BCs and etc. into a file then read this file for

different cases for easy setup for the models

  • Comparison between mapped interfaces with direct and indirect mapping for both conformal and

non- conformal grids

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Thanks for your attention