We present a finite volume adaptive mesh refinement method for solid-liquid phase change problems with convection. The refinement criterion consisted of three different error estimators for the solid-liquid interface, the flow field, and the temperature field respectively. For the solid-liquid interface, the cells undergoing phase change were refined based on the maximum difference in the liquid fraction over the cell faces. For the flow field and the temperature field, an error indicator was used based on the cell residual method. To maintain a high parallelization efficiency, a dynamic load balancing procedure was used. The adaptive mesh refinement strategy was verified through three different test cases, these are the gallium melting in both 2D and 3D cavities, and the molten salt reactor freeze valve. For all three cases, very good agreement was obtained between the adaptive mesh results and the reference solutions. In addition, more accurate results were obtained with the adaptive meshes compared to static meshes with a similar amount of mesh cells. This illustrated the potential of the current approach for developing computationally efficient numerical methods for solid-liquid phase change problems.

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This work presents two color LIF temperature measurements for the transient freezing in a square channel under laminar flow conditions. This is the first time non-intrusive temperature measurements were performed within the thermal boundary layer during the transient growth of an ice layer in internal flow. A combination of a local outlier factor algorithm and a smoothing operation was used to remove the top to bottom striations and reduce the other measurement noise. The temperature uncertainty in our measurements was between σ=0.3∘C and σ=0.5∘C. For the largest temperature difference between the bulk and the melting point of 14.6 °C, good results were obtained. As such, the current campaign demonstrates the potential of LIF as a non-intrusive temperature measurement technique for solid–liquid phase change experiments. However, some artefacts were present within the vicinity of the ice-layer due to the scattering of the laser light, especially near the inlet of the channel where the ice-layer is curved instead of flat. LIF measurements taken within a short time span prior to the onset of ice freezing showed approximately 2 °C of subcooling, consistent with previous findings. In addition, an anomalous behavior within the thermal boundary layer was observed, with a much smaller temperature gradient within the first few mm above the cold plate and a point of inflection in the temperature profile. The anomalous temperature behavior is possibly attributed to enhanced natural convection as a result of the subcooling at the cold plate surface.

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In the present study, we have applied a combined wall-resolving dynamic Large-Eddy Simulation (LES) (for the velocity field) and Direct Numerical Simulation (DNS) (for the temperature field) approach for mixing of parallel triple-jets with different temperatures of liquid sodium in a turbulent forced convection regime. Because of the high thermal conductivity of sodium (a low-Prandtl fluid), we adopted the dynamic Smagorinsky subgrid closure for the unresolved velocity scales, while the thermal scales are fully resolved. Furthermore, the Time-dependent Reynolds-Averaged Navier-Stokes (T-RANS) approach with the high-Reynolds number variant (i.e. with the wall functions as boundary conditions along solid boundaries) of the four-equation eddy viscosity model (k−ε−k_θ−ε_θ) was applied. The fine-mesh LES/DNS provided a close agreement with the experimental data for both velocity and temperature fields (for both first- and second-moments). In contrast, the coarse-mesh LES/DNS overestimated the turbulent kinetic energy profiles at different distances from the inlet plane. The T-RANS results confirmed a good agreement with the mean streamwise velocity and turbulent kinetic energy, as well as the mean temperature profiles. Finally, the analysis of power spectral density distributions of the temperature signal revealed that all simulation techniques captured a dominant flow frequency originating from the induced Kelvin-Helmholtz instabilities between the side and central jets. The presented combined dynamic LES/DNS approach is recommended for future simulations of the turbulent forced convection flows of low Prandtl fluids, especially if thermal fatigue effects need to be predicted correctly.

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Over the next couple of decades, the world will face the challenge of drastically reducing carbon emissions. Innovative Generation-IV nuclear reactor designs can play an important role in driving this energy transition. One of these designs is the Molten Salt Fast Reactor (MSFR), characterized by a fast neutron spectrum and the use of a liquid fuel. Because of the liquid fuel, melting and solidification phenomena need to be considered. To this end, this thesis presents a combined experimental and numerical investigation of melting and solidification phenomena in the MSFR. The experimental part was primarily motivated by the lack of suitable experimental data for the transient development of an ice-layer in internal flow, which is a relevant case for the analysis of accident scenarios in a MSFR where solidification may pose a risk. The main focus of the numerical part was to improve the computational efficiency of current state-of-the-art melting and solidification models.

As part of the experimental investigation, a new experimental facility (ESPRESSO) was designed and built. The ESPRESSO facility consists of a water tunnel capable of reaching both laminar and turbulent flow rates, in which ice is grown from a cold plate at the bottom of a square channel. The ESPRESSO facility was designed to have well-described experimental boundary conditions, through careful consideration of the inflow and cold-plate specifications. Subsequently, experimental data was generated for the transient development of an ice layer in laminar internal flow using particle image velocimetry (PIV), which may be used for numerical validation. The onset of ice formation was found to coincide with a sudden increase of the cold-plate temperature, which was therefore used to identify the zero time instant in our experiments. This was attributed to subcooling effects prior to nucleation, of which evidence was obtained using laser induced fluorescence (LIF) temperature measurements.

In addition, non-intrusive temperature measurements have been performed for the transient development of an ice layer in laminar channel flow using LIF, which is so far only the second application of LIF as a non-intrusive temperature measurement technique in solid-liquid phase change experiments. The LIF method presented in this thesis is a novel approach for solid-liquid phase change experiments because of the use of a two color (instead of a one color) technique, the use of a post-processing algorithm to remove top to bottom striations and reduce other measurement noise, and a detailed analysis of the uncertainty in the temperature fields. Good results were obtained for sufficiently large temperature differences of approximately C with an uncertainty of σ=0.3-0.5 °C, however further improvements are needed to remove artefacts as a result of laser light scattering from the solid-liquid interface, and to obtain a sufficiently high accuracy for numerical validation purposes, especially for smaller temperature differences.

The numerical work performed as part of this thesis aims to address the need for more efficient melting and solidification models, which can accurately capture the solid-liquid interface and resolve the recirculation zones in the fluid region at a lower computational cost. To this end, an energy-conservative DG-FEM approach based on the `linearized enthalpy melting/solidification model' was developed and validated. Although certain solid-liquid phase change problems with strong gradients in the flowfield can benefit from the use of the higher order DG-FEM method, overall a suboptimal O(h) mesh convergence rate was obtained due to an inaccurate numerical solution of the discontinuities at the solid-liquid interface. Therefore, further development of the DG-FEM solid-liquid phase change solver is needed to fully benefit from the arbitrarily high order of accuracy of the hierarchical polynomial basis function set.

Very promising results were obtained with a parallel finite volume adaptive mesh refinement method for solid-liquid phase. Cells were refined based on the maximum difference in the liquid fraction over the cell faces and the estimated numerical discretization error in the flow and temperature fields, using the cell residual method. With this approach, a very good agreement was obtained between the adaptive mesh results and the reference solutions on a uniformly refined grid with significantly less degrees of freedom. This demonstrates the potential of the proposed finite volume adaptive mesh refinement approach as a more computationally efficient numerical method for solid-liquid phase change problems.

The final part of this thesis details a five-stage benchmark for modelling phase change in molten salt reactors, modelled after the MS(F)R freeze-valve design. With each stage, an additional layer of complexity is added, which enabled the identification of potential sources of discrepancy between different numerical modelling approaches. Results were obtained with three different codes: STAR-CCM+, OpenFOAM and DGFlows (inhouse DG-FEM based code for computational fluid dynamics). The results from the benchmark showed an overall good agreement between the three codes, although some discrepancies were observed when adding conjugate heat transfer effects. Therefore, we recommend some caution when coupling different solid-liquid phase change and conjugate heat transfer modelling approaches.

To summarize, this thesis presents new experimental data for the transient ice-growth in laminar internal flow, driven by a general lack hereof. In addition, this thesis illustrates the potential of LIF as a non-intrusive temperature measurement technique for solid-liquid phase change experiments. Two new numerical methods were developed and validated for solid-liquid phase change problems, and especially the finite volume adaptive mesh refinement approach showed promising results in terms of enhanced computational efficiency. On a final note: solid-liquid phase change is a vast and ongoing field of research. We believe this thesis is a substantial addition to the field, yet there are still a lot of opportunities for future work. Some suggestions are given in the concluding chapter.
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The design of a molten salt reactor is largely based on CFD simulations. Phase change plays an important role in the safety of the reactor, but numerical modelling of phase change is particularly challenging. Therefore, the knowledge of the margin of error of CFD simulations involving phase change is very important. Relevant experimental validation data is lacking. For this reason, a numerical benchmark designed after the freeze valve is proposed. The benchmark consists of five stages, where with each step more complexity is added. The step-wise addition of complexity allows for pinpointing potential sources of discrepancy. Results were obtained with three different codes: STAR-CCM+, OpenFOAM, and DGFlows. The results were found to be largely consistent between the codes, however the addition of conjugate heat transfer introduced some discrepancies. These results indicate that careful consideration is needed when coupling conjugate heat transfer solvers with solid–liquid phase change models.

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We present a discontinuous Galerkin method for melting/solidification problems based on the “linearized enthalpy approach,” which is derived from the conservative form of the energy transport equation and does not depend on the use of a so-called mushy zone. We use the symmetric interior penalty method and the Lax–Friedrichs flux to discretize diffusive and convective terms, respectively. Time is discretized with a second-order implicit backward differentiation formula, and two outer iterations with second-order extrapolation predictors are used for the coupling of the momentum and energy. The numerical method was validated with three different benchmark cases, i.e., the one-dimensional Stefan problem, octadecane melting in a square cavity and gallium melting in a rectangular cavity. The performance of the method was quantified based on the L ² norm error and the number of iterations needed to convergence the energy equation at each time step. For all three validation cases, a mesh convergence rate of approximately O(h) was obtained, which is below the expected accuracy of the numerical method. Only for the gallium melting case, the use of a higher-order method proved to be beneficial. The results from the present numerical campaign demonstrate the promise of the discontinuous Galerkin finite element method for modeling certain solid–liquid phase change problems where large gradients in the flow field are present or the phase change is highly localized, however, further enhancement of the method is needed to fully benefit from the use of a higher-order numerical method when solving solid–liquid phase change problems.

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