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Water-Cooled Target Studies: Single Solid Rod

Water-Cooled Target Studies: Single Solid Rod. J.Popp, B.Christensen, C.Chen, W.Molzon, J.Carmona, R.Rangel, J.LaRue University of California, Irvine. Outline. Target design calculations Optimizing flow and heat & mass transfer properties Test stand construction Equipment selection

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Water-Cooled Target Studies: Single Solid Rod

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  1. Water-Cooled Target Studies: Single Solid Rod J.Popp, B.Christensen, C.Chen, W.Molzon, J.Carmona, R.Rangel, J.LaRue University of California, Irvine

  2. Outline • Target design calculations • Optimizing flow and heat & mass transfer properties • Test stand construction • Equipment selection • Mechanical design and layout • Prototype fabrication and flow trials • Water channel design • Inlet/outlet geometry • Rod support and surface preparation • Induction heating tests • Coolant containment shell • Rod material • Power supply and coil Jim Popp, UCI Water-Cooled Target Studies

  3. Annular water channel Gap, h: 0.2  0.5 mm Radius, R: 0.3, 0.4 cm Length, L: 16.0, 20.0 cm Uniform heating L = 16.0 cm, 0 W L = 16.0 cm, 9500 W L = 20.0 cm, 11875 W Volumetric flow rate: 0.5 – 2.6 gpm Inlet water temperature: 20.0 C Surface roughness Viscosity:  = (T) End view: Axial symmetry Cut-away side view 3D  2D: T = T(r,z) water r target z Inlet Outlet Model Parameters: Steady State Problem Jim Popp, UCI Water-Cooled Target Studies

  4. r z CFDesign: Numerical Solution for Velocity, Vz(r,z) 12.3 m/s • Water: Solve coupled equations • Viscous fluid • Heat transport • Steady state problem • Mesh points: 12000 - 31000 • Turbulent flow • Inlet: Re = 4600 - 23000 • Outlet: Re = 15000 - 31900 • Boundary conditions • Constant heat flux: P = 9500 W • Containment shell: Adiabatic wall • Inlet water conditions • T = 20 C • Flow = 2.11 gpm • Flow channel • L = 16.0 cm • R = 4.0 mm • h = 0.5 mm Entry Region Coolant containment wall Target 0.0 m/s Jim Popp, UCI Water-Cooled Target Studies

  5. r z Inlet Velocity Boundary Condition Discharge rate, Q: • Boundary conditions for all calculations are identical. - Uniform fluid velocity at entrance • Entry region: 7.3 mm,  15 water gaps • Beyond entry region  fully developed turbulent flow Jim Popp, UCI Water-Cooled Target Studies

  6. Target Coolant containment wall 0.0 mm 0.5 mm Radial distance from target surface Effect of Temperature on Viscosity, (T)Velocity Profile Beyond Entry Region 12 m/s Constant properties: (water at 20oC)  = 0.001 kg/m·s,  = 998.2 kg/m3 Variable properties:  = (T)  = (T) 0 m/s Jim Popp, UCI Water-Cooled Target Studies

  7. Target Coolant containment wall Radial distance from target surface Effect of Temperature on Viscosity, (T)Temperature Profile at Outlet 350 K Constant props:  = 0.001 kg/m·s,  = 998.2 kg/m3 (water at 20oC) Variable props:  = (T),  = (T) 300 K 0.0 mm 0.5 mm Jim Popp, UCI Water-Cooled Target Studies

  8. Results: Pressure & Temperature L = 160 mm R = 4 mm P = 9500 W h = gap size Maximum local water temperature always at target surface near outlet Jim Popp, UCI Water-Cooled Target Studies

  9. Local Temperature Rise vs Flow R = 4 mm L = 16 cm h = 0.4 mm P = 9500 W Jim Popp, UCI Water-Cooled Target Studies

  10. Pressure Drop vs Gap Size at Fixed DT R = 4 mm L = 16 cm P = 9500 W Jim Popp, UCI Water-Cooled Target Studies

  11. Test Stand Construction • Plumbing • 316 SS • Teflon hose with braided SS cover • PVC • Reservoir – 90 gal • Rotary Vane Pump • Max 5.26 gpm • Max 240 psi • Non-pulsing • Sensors • 2 Pressure • Inlet & outlet • 2 Temperature • Reservoir • Outlet • 1 Volumetric Flow Jim Popp, UCI Water-Cooled Target Studies

  12. Test Stand Repeatability Jim Popp, UCI Water-Cooled Target Studies

  13. Prototype 1 & 2 End Cap Design • Radius: 3 mm • Gap: 0.3 mm • Length: 16 cm • Prototype 1 • Welded • Prototype 2 • Silver soldered • Polished interior surfaces Jim Popp, UCI Water-Cooled Target Studies

  14. Prototype 1 & 2 Rod and Shell Design Units: inches Shell: 304 SS Rod: Aluminum Jim Popp, UCI Water-Cooled Target Studies

  15. Prototype 2 Data • Annular channels • Without right-angle turns • With right-angle turns • Measurements include • Inlet  to channel • Target feet Jim Popp, UCI Water-Cooled Target Studies

  16. Note fluid circulation in shadow region r z Right-Angle Geometry Inlet Axial Velocity, Vz(r,z) 10 m/s Coolant containment wall Target Zoom on right 0 m/s -2 m/s Nipple length = 5.1 mm Water gap = 0.5 mm Jim Popp, UCI Water-Cooled Target Studies

  17. r z Right-Angle Geometry Inlet Radial Velocity, Vr(r,z) 6 m/s 0 Coolant containment wall Target Zoom on right -6 m/s Nipple length = 5.1 cm Water gap = 0.5 mm Jim Popp, UCI Water-Cooled Target Studies

  18. Coolant containment wall Target r z Right-Angle GeometryOutlet Axial Velocity, Vz(r,z) 10 m/s Zoom on right 0 m/s -2 m/s Nipple length = 5.1 cm Water gap = 0.5 mm Jim Popp, UCI Water-Cooled Target Studies

  19. r z Right-Angle Geometry Outlet Radial Velocity, Vr(r,z) 6 m/s 0 Coolant containment wall Target Zoom on right -6 m/s Nipple length = 5.1 cm Water gap = 0.5 mm Jim Popp, UCI Water-Cooled Target Studies

  20. Right-Angle Geometry: Pressure Jim Popp, UCI Water-Cooled Target Studies

  21. Prototype 3 End Caps Jim Popp, UCI Water-Cooled Target Studies

  22. Prototype 3 Rod and Shell • Units: inches • Taper: • 4 gap rise • 1 cm run Jim Popp, UCI Water-Cooled Target Studies

  23. Prototype 3 Data Jim Popp, UCI Water-Cooled Target Studies

  24. 13.7 m/s Coolant containment wall Target r z 0.0 m/s Tapered Rod Hybrid GeometryMagnitude ofVelocityat Inlet Jim Popp, UCI Water-Cooled Target Studies

  25. r z Tapered Rod Hybrid Geometry Inlet Axial Velocity, Vz(r,z) 12.0 m/s Coolant containment wall Zoom on right Target 0.0 m/s -1.3 m/s Rise 4 water gaps over 1 cm Water gap = 0.3 mm Jim Popp, UCI Water-Cooled Target Studies

  26. r z Tapered Rod Hybrid Geometry Inlet Radial Velocity, Vr(r,z) 1.1 m/s 0 m/s Coolant containment wall Target Zoom on right -2.5 m/s Rise 4 water gaps over 1 cm Water gap = 0.3 mm Jim Popp, UCI Water-Cooled Target Studies

  27. r z Tapered Rod Hybrid GeometryMagnitude of Velocity at Outlet 13.7 m/s Coolant containment wall Target Flow separation from rod surface 0.0 m/s Jim Popp, UCI Water-Cooled Target Studies

  28. r z Tapered Rod Hybrid Geometry Outlet Velocity Vz(r,z) 13.7 m/s Coolant containment wall Target 0 m/s -1.3 m/s Jim Popp, UCI Water-Cooled Target Studies

  29. r z Tapered Rod Hybrid Geometry Outlet Velocity Vr(r,z) 1.1 m/s 0.0 m/s -2.5 m/s Jim Popp, UCI Water-Cooled Target Studies

  30. Other Effects: Surface Roughness, ks • Higher wall shear • Higher pressure drop • Increase in Nusselt number (heat transfer factor)  lower local temperatures due to better mixing Absolute surface roughness, ks , is a length scale • R = 4 mm, L = 16 cm, h = 0.5 mm, Power = 9500 W, Q = 2.11 gpm Jim Popp, UCI Water-Cooled Target Studies

  31. Target Coolant containment wall Radial distance from target surface (m) Other Effects: Surface Roughness – Vz(r) Jim Popp, UCI Water-Cooled Target Studies

  32. Target Coolant containment wall Radial distance from target surface (m) Other Effects: Surface Roughness Local Temperature at Outlet Jim Popp, UCI Water-Cooled Target Studies

  33. Other Effects: Surface Roughness - Viscosity Coolant containment wall Target Radial distance from target surface (m) Jim Popp, UCI Water-Cooled Target Studies

  34. Other Effects: Inlet & Outlet Pipes Additional pressure drop Tube length = 30 cm ID = 0.082” (2.08 mm) OD = 0.125” (3.20 mm) Wall thickness = .0215” (.546 mm) Jim Popp, UCI Water-Cooled Target Studies

  35. Induction Heating Principle • EM waves penetrate metal  heating • Skin depth: • Semi-infinite slab • Power/unit area: • Magnetic field for infinite solenoid: • Need to select • rod material (,) • power supply (w=2pf,P, I) • copper coil (n) • shell material  non-conducting • Desired Power = 9500 W Jim Popp, UCI Water-Cooled Target Studies

  36. Target Materials and Power Supply • I = 40 A • n = 100 turns/m • Rod radius = .3 cm • Supermalloy – 75% Ni, 5% Mo, 16% Fe • 400 Series SS – 14% Cr, .5% Ni, .12% C 1% Mn, 84% Fe Jim Popp, UCI Water-Cooled Target Studies

  37. Prototype 4: Induction Heating Units: inches Transparent containment shell Inlet & outlet positioned away from rod axis for better mixing Holes in threaded end caps allow sensors to monitor target temperature Jim Popp, UCI Water-Cooled Target Studies

  38. Prototype 4: End & Top View Note: inlet & outlet actually positioned off axis Jim Popp, UCI Water-Cooled Target Studies

  39. Prototype 4: 3D Views • Same flow geometry as prototype 3 • O-rings on ends • Allows for rod expansion • High pressure plastic inlet & outlet pipes and fittings (not shown) Jim Popp, UCI Water-Cooled Target Studies

  40. r z Prototype 5: Motivation for Target Fins Coolant containment wall Target Zoom on right Target h = 0.5 mm Left end of figure, z = 0.14 m Right end of figure, z = 0.15 m Temperature range: 293.1 (blue) – 350.0 (red) K Jim Popp, UCI Water-Cooled Target Studies

  41. Prototype 5: Target with 175 Fins Dimensions in mm Jim Popp, UCI Water-Cooled Target Studies

  42. Prototype 5: End View Close-Up • Dimensions = mm • Open region = 0.16 mm • 3 mm radius shown • Flow region simulated • 7 times surface area of prototype 3 Jim Popp, UCI Water-Cooled Target Studies

  43. Prototype 5: 3D Calculation Discrete symmetry  compute ½ fin Dimensions << R  Rectangular coordinates On-going study Mesh optimization needed Jim Popp, UCI Water-Cooled Target Studies

  44. y x End View: Axial Velocity, Vz(x,y) Height: 0.048 mm Width: 0.1 mm & 0.05 mm 16 m/s 0 m/s Jim Popp, UCI Water-Cooled Target Studies

  45. y y z z Side View: Axial Velocity, Vz(y,z) • Axial velocity at middle of channel between fins: • Axial velocity up against the fin: Pressure drop = 1300 psi Reduce: number of fins & fin height Jim Popp, UCI Water-Cooled Target Studies

  46. Conclusion: What’s Next? • Continue 2D studies of prototypes • Mesh refinement • Pulsed (in time) longitudinal energy distribution • Continue 3D studies • Mesh refinement • Fin design • Improve mixing in flow channels • Reduce overall operating pressures • Further design inlet and outlets: move off rod axis for better mixing • Conduct induction heating tests • Make test stand portable • Install heat exchanger and booster pump • Continue flow & pressure studies Jim Popp, UCI Water-Cooled Target Studies

  47. Appendix 1: Ri = 4 mm, L = 160 mm, P = 225 W/cm2 Jim Popp, UCI Water-Cooled Target Studies

  48. Appendix 2:Ri = 3 mm, L = 160 mm, P = 300 W/cm2 • Higher pressure drop • Higher local temperatures Jim Popp, UCI Water-Cooled Target Studies

  49. Appendix 3: Ri = 4 mm, L = 200 mm, P = 225 W/cm2 • Higher pressure drop • Higher local temperatures • Higher mean temperature at outlet Jim Popp, UCI Water-Cooled Target Studies

  50. Circular pipe In general Appendix 4: Turbulent Flow Jim Popp, UCI Water-Cooled Target Studies

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