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All sourcesNASA NTRSDOE OSTI
DOE OSTI2016

Investigation of Natural Circulation Instability and Transients in Passively Safe Small Modular Reactors

The NEUP funded project, NEUP-3496, aims to experimentally investigate two-phase natural circulation flow instability that could occur in Small Modular Reactors (SMRs), especially for natural circulation SMRs. The objective has been achieved by systematically performing tests to study the general natural circulation instability characteristics and the natural circulation behavior under start-up or design basis accident conditions. Experimental data sets highlighting the effect of void reactivity feedback as well as the effect of power ramp-up rate and system pressure have been used to develop a comprehensive stability map. The safety analysis code, RELAP5, has been used to evaluate experimental results and models. Improvements to the constitutive relations for flashing have been made in order to develop a reliable analysis tool. This research has been focusing on two generic SMR designs, i.e. a small modular Simplified Boiling Water Reactor (SBWR) like design and a small integral Pressurized Water Reactor (PWR) like design. A BWR-type natural circulation test facility was firstly built based on the three-level scaling analysis of the Purdue Novel Modular Reactor (NMR) with an electric output of 50 MWe, namely NMR-50, which represents a BWR-type SMR with a significantly reduced reactor pressure vessel (RPV) height. The experimental facility was installed with various equipment to measure thermalhydraulic parameters such as pressure, temperature, mass flow rate and void fraction. Characterization tests were performed before the startup transient tests and quasi-steady tests to determine the loop flow resistance. The control system and data acquisition system were programmed with LabVIEW to realize the realtime control and data storage. The thermal-hydraulic and nuclear coupled startup transients were performed to investigate the flow instabilities at low pressure and low power conditions for NMR-50. Two different power ramps were chosen to study the effect of startup power density on the flow instability. The experimental startup transient results showed the existence of three different flow instability mechanisms, i.e., flashing instability, condensation induced flow instability, and density wave oscillations. In addition, the void-reactivity feedback did not have significant effects on the flow instability during the startup transients for NMR-50. ii Several initial startup procedures with different power ramp rates were experimentally investigated to eliminate the flow instabilities observed from the startup transients. Particularly, the very slow startup transient and pressurized startup transient tests were performed and compared. It was found that the very slow startup transients by applying very small power density can eliminate the flashing oscillations in the single-phase natural circulation and stabilize the flow oscillations in the phase of net vapor generation. The initially pressurized startup procedure was tested to eliminate the flashing instability during the startup transients as well. The pressurized startup procedure included the initial pressurization, heat-up, and venting process. The startup transient tests showed that the pressurized startup procedure could eliminate the flow instability during the transition from single-phase flow to two-phase flow at low pressure conditions. The experimental results indicated that both startup procedures were applicable to the initial startup of NMR. However, the pressurized startup procedures might be preferred due to short operating hours required. In order to have a deeper understanding of natural circulation flow instability, the quasi-steady tests were performed using the test facility installed with preheater and subcooler. The effect of system pressure, core inlet subcooling, core power density, inlet flow resistance coefficient, and void reactivity feedback were investigated in the quasi-steady state tests. The experimental stability boundaries were determined between unstable and stable flow conditions in the dimensionless stability plane of inlet subcooling number and Zuber number. To predict the stability boundary theoretically, linear stability analysis in the frequency domain was performed at four sections of the natural circulation test loop. The flashing phenomena in the chimney section was considered as an axially uniform heat source. And the dimensionless characteristic equation of the pressure drop perturbation was obtained by considering the void fraction effect and outlet flow resistance in the core section. The theoretical flashing boundary showed some discrepancies with previous experimental data from the quasi-steady state tests. In the future, thermal non-equilibrium was recommended to improve the accuracy of flashing instability boundary. As another part of the funded research, flow instabilities of a PWR-type SMR under low pressure and low power conditions were investigated experimentally as well. The NuScale reactor design was selected as the prototype for the PWR-type SMR. In order to experimentally study the natural circulation behavior of NuScale iii reactor during accidental scenarios, detailed scaling analyses are necessary to ensure that the scaled phenomena could be obtained in a laboratory test facility. The three-level scaling method is used as well to obtain the scaling ratios derived from various non-dimensional numbers. The design of the ideally scaled facility (ISF) was initially accomplished based on these scaling ratios. Then the engineering scaled facility (ESF) was designed and constructed based on the ISF by considering engineering limitations including laboratory space, pipe size, and pipe connections etc. PWR-type SMR experiments were performed in this well-scaled test facility to investigate the potential thermal hydraulic flow instability during the blowdown events, which might occur during the loss of coolant accident (LOCA) and loss of heat sink accident (LOHS) of the prototype PWR-type SMR. Two kinds of experiments, normal blowdown event and cold blowdown event, were experimentally investigated and compared with code predictions. The normal blowdown event was experimentally simulated since an initial condition where the pressure was lower than the designed pressure of the experiment facility, while the code prediction of blowdown started from the normal operation condition. Important thermal hydraulic parameters including reactor pressure vessel (RPV) pressure, containment pressure, local void fraction and temperature, pressure drop and natural circulation flow rate were measured and analyzed during the blowdown event. The pressure and water level transients are similar to the experimental results published by NuScale [51], which proves the capability of current loop in simulating the thermal hydraulic transient of real PWR-type SMR. During the 20000s blowdown experiment, water level in the core was always above the active fuel assemble during the experiment and proved the safety of natural circulation cooling and water recycling design of PWR-type SMR. Besides, pressure, temperature, and water level transient can be accurately predicted by RELAP5 code. However, the oscillations of natural circulation flow rate, water level and pressure drops were observed during the blowdown transients. This kind of flow oscillations are related to the water level and the location upper plenum, which is a path for coolant flow from chimney to steam generator and down comer. In order to investigate the transients start from the opening of ADS valve in both experimental and numerical way, the cold blow-down experiment is conducted. For the cold blowdown event, different from setting both reactor iv pressure vessel (RPV) and containment at high temperature and pressure, only RPV was heated close to the highest designed pressure and then open the ADS valve, same process was predicted using RELAP5 code. By doing cold blowdown experiment, the entire transients from the opening of ADS can be investigated by code and benchmarked with experimental data. Similar flow instability observed in the cold blowdown experiment. The comparison between code prediction and experiment data showed that the RELAP5 code can successfully predict the pressure void fraction and temperature transient during the cold blowdown event with limited error, but numerical instability exists in predicting natural circulation flow rate. Besides, the code is lack of capability in predicting the water level related flow instability observed in experiments.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2017

Standard Modular Hydropower Technology Acceleration Workshop: Summary Report

In support of the Department of Energy (DOE) funded Standard Modular Hydropower (SMH) Technology Acceleration project, Oak Ridge National Laboratory (ORNL) staff convened with five small hydropower technology entrepreneurs on June 14 and 15, 2017 to discuss gaps, challenges, and opportunities for small modular hydropower development. The workshop was designed to walk through SMH concepts, discuss the SMH research vision, assess how each participant’s technology aligns with SMH concepts and research, and identify future pathways for mutually beneficial collaboration that leverages ORNL expertise and entrepreneurial industry experience. The goal coming out of the workshop is to advance standardized, scalable, modular hydropower technologies and development approaches with sustained and open dialogue among diverse stakeholder groups.

43 PARTICLE ACCELERATORS↗
DOE OSTI2019

Modular Plane Stress Plasticity Material Model

A variety of recent work has expanded capabilities in LAMÉ with respect to anisotropic and modular plasticity model. In this context, modular refers to a flexible framework and consistent implementation such that different hardening functional forms may all be incorporated into the same material model implementation rather than needing a new model for each description. However, such work has been focused on three-dimensional formulations and limited attention has been paid to structural formulations; i.e. for use with beam or shell elements. As a first step to bringing some of these recent advances towards structural elements, modular isotropic hardening capabilities will be added to the J2 von Mises plane-stress plasticity formulation of Simo and Taylor. To accomplish this effort, in Section 2 and 3 the theory and numerical formulation of the model are given. Specific functional forms of the hardening and example syntax to use them are then presented in Section 4 while verification exercises are documented in Section 5. Finally, some concluding thoughts about future work are given in Section 6.

36 MATERIALS SCIENCE↗
DOE OSTI2021

Staged OMB for Modular Gasifier/Burner

The goal of this final project report is to comprehensively summarize the work conducted on project DE-FE0031506. In accordance with the Statement of Project Objectives (SOPO), the University of Kentucky Center for Applied Energy Research (UK CAER) (Recipient) has developed a staged opposed multi-burner (OMB) gasifier, scaled down from a commercial gasification technology to utilize coal slurry as feed for the high-temperature gasification. The project involved the design, fabrication, commissioning, parametric testing, and performance validation of the entrained gasifier with multiple burners to narrow the major near-term technical gaps that impede the application of small-size gasification by modularizing the system. Project results verified the UK CAER approach to address the major technical challenges on the gasification modularization for a distributed application at a small scale of 1-5 MWe, while maintaining advantages in cost and flexibility, which include: 1) a cost-effective burner configuration to provide high flexibility in both load and fuel feed; 2) the modularized staged-OMB to provide better gasification performance such as a desired temperature profile, better fuel conversion, better gasification efficiency, and long lifetimes of the refractory wall and burners; and 3) load control simply through changing the number of burners firing. UK CAER’s staged gasifier configuration, fuel blend performance, and economic evaluation shows promise, as summarized in this report, as an effective means for improved gasification efficiency with reduced operation cost and process complexity.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

Manufacturing Supply Chain Development for Modular Solar-Thermochemical Conversion Platform - CRADA 387 (Final Report)

Modular chemical process intensification (MCPI) is an emerging field where chemical processing is performed using small-scale modular equipment instead of conventional large centralized chemical plants. Conventional chemical plants benefit from economies of scale that encourage scale-up to ever larger plants. A goal of MCPI is to develop technology that intensifies processing so that equipment can be dramatically smaller and integrated into modular systems. Scale-up occurs by adding more modules in parallel rather than making the equipment larger. A key concept is that equipment and modules can ultimately be cheaper by leveraging economies of mass production, analogous to the automotive industry, in manufacturing the equipment. This project made significant progress toward this outcome by meeting the RAPID institute metric to reduce equipment cost by 20% for each doubling in manufacturing volume. The MCPI application was thermochemical technology that is being commercialized by STARS Technology Corporation, one of the CRADA partners. The technology converts solar and renewable power to chemical energy to produce renewable hydrogen, fuels, and chemicals. The benefit to the public is reduction in greenhouse gases that are contributing to climate change. The project transitioned the steam methane reforming (SMR) reactor from conventional fabrication methods to additive manufacturing (AM) direct metal laser sintering (DMLS) process. This is projected to reduce the cost of making a reactor by 58% when producing 100 reactors per year. Innovations in the DMLS process produced a patented design that reduces reactor weight by 60%. Reductions in material costs and processing time extend the DMLS advantage to higher production volumes. The new design promises to be 38% cheaper than the conventional processes at 1000 units per year. The resulting 87% reduction in the steam methane reforming (SMR) module cost in scaling from current costs meets the RAPID metric. The project was successful in producing and testing the first ever additively manufactured SMR reactors. A reactor achieved over 82% efficiency in converting electric power to chemical energy, which is a world record for an inductively heated SMR. The project has contributed to the design and assembly of a first demonstration plant that is headed to a hydrogen bus filling station in Thousand Palms, CA.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2024

Modularization of Ceramic Hollow Fiber Membrane Technology for Air Separation

This proposed project is aimed at studying high performance and economically competitive ceramic membrane technology for air separation and high-purity oxygen production using hollow fiber ceramic membrane stack and module technology. The design of the single permeate membrane is a hollow fiber substrate-supported thin tri-layer structure. Radially well-aligned micro-channels are embedded in the thick substrate and open at the inner surface of the substrate, enabling facile air/gas diffusion. The tri-layer structure of thin dense membrane layer (~ 10 µm) sandwiched by porous surface layer on either side is then built on the substrate using advanced fabrication process. The tri-layer structure design allows different materials to be used in different layers, where the materials of surface layers have high surface exchange coefficients while the material of dense layer has high bulk diffusivity. Such a synergetic combination leads to high permeation performance. The focus of the proposed project will be on membrane stack/module development using the developed single hollow fiber membranes, including: 1) fabrication and characterization of novel single hollow fiber membranes; 2) membrane stack design and assembly using fabricated single membranes; 3) stack modeling and analysis to guide membrane stack designs; 4) permeation performance testing and characterization of membrane stacks. The hollow fiber feature and simple sealing requirement enable very compact design of membrane stacks, which have excellent flexibility for further modularizations at different scales. The operations of such membrane stack and module may employ the exhaust heat from other components of Integrated Gasification Combined Cycle and oxy-combustion systems. Therefore, modularization of such an air separation membrane technology can be incorporated into the DOE’s REMS (radically engineered modular systems)-gasification skid and support the oxidant feed of an oxygen-blown REMS gasifier scaled to different ranges.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2024

A Modular Oxygen-Selective System for Combustion Systems

Small-scale modular systems for oxygen generation offer clear benefits, including improved energy efficiency, reduced operating costs, and the flexibility to meet location-specific needs. We propose that a compact modular system could be developed using a solvent-based method for capturing and releasing oxygen, enabling “oxygen on demand” for various combustion technologies. In this project, we aim to develop and demonstrate a modular oxygen-selective approach based on Battelle IPID 31740. The use of designer solvents, which are reversible, single-component solvents capable of dissolving and separating oxygen from air, offers the advantage of unlimited chemical tunability to achieve desirable properties for efficient oxygen separation. We filed U.S. Patent (32845-E, iEdison No. 0685901-23-0184).

36 MATERIALS SCIENCE↗
DOE OSTI2025

Modular Processing of Flare Gas for Carbon Nanoproducts

This project demonstrated the technical viability and economic promise of a modular system for converting flared natural gas into valuable carbon nanoproducts (CNPs) through catalytic chemical vapor deposition (CVD). All major project milestones were successfully completed, including reactor design and commissioning, catalyst development, process optimization, technoeconomic analysis, and application testing in concrete systems. The overarching goal was to create a scalable, field-deployable process that valorizes stranded methane by producing high-value carbon materials for use in cementitious composites. At the lab scale, the team designed and built a fluidized bed reactor optimized for use with silica fume-supported nickel catalysts synthesized via atomic layer deposition (ALD). A statistically designed sintering study enabled precise tuning of nickel nanoparticle size, identifying the influence of oxygen partial pressure, time, and temperature on catalyst morphology and performance. These insights allowed the team to target catalyst conditions that maximize carbon nanofilament growth. Subsequent CVD experiments achieved up to 31.8 wt% carbon deposition under optimized conditions, with TEM confirming the presence of nanofilament structures and sustained hydrogen evolution during reaction. Reactor upgrades and empirical fluidization studies supported the development of reliable, repeatable experimental protocols. The modular pilot-scale skid reactor was fully constructed, instrumented, and commissioned. Capable of operating at 675–800°C and pressures up to 290 psig, the system was designed for continuous operation at a carbon production rate of 1 kg/hr. Initial demonstration runs confirmed solids handling, thermal control, and system leak-tightness, although a critical reactor component (the downfeed tube) was inadvertently omitted during final assembly. This omission limited gas–solid contact and prevented meaningful carbon deposition during pilot-scale CVD runs. Nonetheless, the system operated safely under design conditions, and the root cause of performance limitations was clearly identified. Complementary work on UHPC formulations demonstrated that small additions of carbon nanoproducts, including those derived from flare gas, can significantly enhance mechanical performance while preserving workability. A comprehensive study of CNF dispersion techniques and mix design optimization led to a clear protocol for integrating these nanomaterials into concrete. Incorporation of CNPs improved flexural toughness and reduced porosity, supporting their use in high-performance infrastructure applications. A technoeconomic analysis (TEA) confirmed that this process can produce CNP-loaded catalyst material at a levelized cost below $\$$7/kg across a range of catalyst loadings and reaction yields. With estimated market values for the carbon composite product ranging from $\$$14 to over $\$$60/kg, and the ability to blend CNPs into concrete at sub-percent levels with less than 10% added cost, the system presents a compelling economic case. While additional engineering work is needed to optimize fluidization and heat transfer at scale, this project establishes a strong foundation for commercial development. The process is not only technically sound but also economically promising, representing a viable pathway for flare gas mitigation through modular carbon nanomaterial production.

03 NATURAL GAS↗
DOE OSTI2025

Model Development for the ACME Lab Modular Wall and A-Frame Assemblies

The structural frame used for conducting large structural tests was replaced by the ACME (Applied Combined Mechanical Environments) Lab in Building 860 of Sandia National Laboratories in Albuquerque, NM. This new design required simulation and analysis to verify maximum loads and corresponding factors of safety. Two major assemblies which are part of the ACME Lab, the Modular Wall and A-Frame, were designed to operate with a multitude of components in various configurations and with varying loads. Simulations of the Modular Wall and A-Frame structures were performed through explicit analysis to determine safety factors for numerous loading scenarios. The Modular Wall had safety factors of 1.1 for the lateral, diagonal, and gusset loading conditions. The A-Frame had safety factors of 2 for all loading conditions simulated.

42 ENGINEERING↗
DOE OSTI2022

A Development of Critical Components for the Modular Staged Pressurized Oxy-Combustion Power Plant

DOE's Coal FIRST (Flexible, Innovative, Resilient, Small, Transformative) Initiative was implemented to encourage the development of the coal plant of the future, which will be capable of flexible operation to meet the needs of the grid; using innovative and cutting-edge components that improve efficiency and reduce emissions; providing resilient power to Americans; being small compared to today's conventional utility-scale coal power plants; and transforming how coal power plant technologies are designed and manufactured. The modular Staged, Pressurized Oxy-Combustion (SPOC) process envisioned by and under development at Washington University in St. Louis (WUSTL) has the potential to achieve these goals. The process offers: 1) a modular plant design for improved operational flexibility; 2) fuel-staging combined with pressurized oxy-combustion, which leads to smaller plant size, higher plant efficiency, and lower cost for pollutant and greenhouse gases removal compared with traditional carbon-capture equipped coal power plants; and 3) small modular boilers and pollutant removal units that can be fabricated in shop and assembled on site, further reducing plant capital costs. Under DOE's support (DE-FE0031925), WUSTL is advancing the development of the critical components for the SPOC power plant, including the integrated combustion system and the direct contact cooler (DCC) from TRL 4 to TRL-5, which would allow them to be subsequently incorporated into a pilot plant. These units are the only two components that are not commercially available for a SPOC plant, and hence, their development is a key step toward the commercialization of SPOC. This work presents the objectives, task descriptions, and current progress of the project. So far, the fabrication of a new combustor design and the convective heat transfer boiler has been completed, and the integration of the combustor, boiler, and DCC is underway. Recent results obtained with the newly designed combustor show a stable coal/methane flame while dry-feeding PRB coal under oxy-combustion conditions.

Magalhaes, Duarte↗
DOE OSTI2023

Modular Staged Pressurized Oxy-Combustion (SPOC) Power Plant for Coal and Biomass – Integration of Combustor Boiler and DCC

Critical to the future of power generation is the development of a power plant that will be capable of flexible operation to meet the needs of the modern grid, providing resilient, low-emissions power to a grid that is increasingly seeing a large penetration of intermittent wind and solar. The modular Staged, Pressurized Oxy-Combustion (SPOC) process envisioned by and under development at Washington University in St. Louis (WUSTL) has the potential to achieve these goals. The process offers: 1) a modular plant design for improved operational flexibility; 2) fuel-staging combined with pressurized oxy-combustion, which leads to smaller plant size, higher plant efficiency, and lower cost for pollutant and greenhouse gas removal compared with traditional carbon-capture equipped coal power plants; and 3) small modular boilers and pollutant removal units that can be fabricated in shop and assembled on site, further reducing plant capital costs. Under DOE's support (DE-FE0031925), WUSTL is advancing the development of the critical components for the SPOC power plant, including the integrated combustion system and the direct contact cooler (DCC) from Technology Readiness Level (TRL) 4 to TRL-5, which would allow these technologies to be subsequently incorporated into a pilot plant. This talk will present an overview of the SPOC technology, CFD modeling and validation for burner and boiler development, and recent results to evaluate critical components for system integration needed to advance its TRL.

Magalhaes, Duarte↗
DOE OSTI2024

Modular Staged Pressurized Oxy-Combustion (SPOC) Power Plant for Coal and Biomass – Integration of Combustor Boiler and DCC

Utilities and grid operators worldwide are under significant pressure to incorporate intermittent renewable sources while strategizing on how to maintain the necessary stability and reliability of the grid. The development of a power plant which will be capable of flexible operation to meet the needs of the grid as more intermittent sources like wind and solar energy are incorporated is key to maintain the reliability of the grid. Through the use of innovative and cutting-edge technologies that improve efficiency and reduce carbon emissions, and being small compared to today's conventional utility-scale power plants, the modular Staged, Pressurized Oxy-Combustion (SPOC) process envisioned by and under development at Washington University in St. Louis (WUSTL) has the potential to achieve these goals. Specifically, the process offers: 1) a modular plant design that allows for better operational flexibility; 2) the utilization of fuel-staging and pressurized oxy-combustion, resulting in smaller plant size, improved plant efficiency, and reduced costs for pollutant and CO2 removal compared to traditional power plants with post-combustion capture technology; and 3) the use of small modular boilers and pollutant removal units that can be constructed off-site leading to reduced capital costs for the plant. WUSTL is advancing the development of the critical components for the SPOC power plant, including the integrated combustor-boiler system and the direct contact cooler. To demonstrate the boiler convective section and to obtain critical data for commercial-scale pressurized boiler design, a simulated convective heat transfer boiler test section was designed and integrated with the combustor (radiant section). A direct contact cooler (DCC) was integrated with the combustor-boiler to demonstrate the dynamic operation of the integrated system and the performance of the DCC, including the efficiency for simultaneous removal of NOx and SOx. This talk will present an update on the evaluation of the critical components for system integration, including heat transfer data from the simulated boiler, scrubbing efficiency for the DCC under different operating conditions, and CFD modeling and validation for burner and boiler development.

Magalhaes, Duarte↗
DOE OSTI2023

Development of the Modular Staged Pressurized Oxy-Combustion (SPOC) Power Plant for Coal and Biomass

Critical to the future of power generation is the development of a power plant that will be capable of flexible operation to meet the needs of the modern grid, providing resilient, low-emissions power to a grid that is increasingly seeing a large penetration of intermittent wind and solar. The modular Staged, Pressurized Oxy-Combustion (SPOC) process envisioned by and under development at Washington University in St. Louis (WUSTL) has the potential to achieve these goals. The process offers: 1) a modular plant design for improved operational flexibility; 2) fuel-staging combined with pressurized oxy-combustion, which leads to smaller plant size, higher plant efficiency, and lower cost for pollutant and greenhouse gases removal compared with traditional carbon-capture equipped coal power plants; and 3) small modular boilers and pollutant removal units that can be fabricated in shop and assembled on site, further reducing plant capital costs. Under DOE's support (DE-FE0031925), WUSTL is advancing the development of the critical components for the SPOC power plant, including the integrated combustion system and the direct contact cooler (DCC) from Technology Readiness Level (TRL) 4 to TRL-5, which would allow these technologies to be subsequently incorporated into a pilot plant. This talk will present an overview of the SPOC technology, CFD modeling and validation for burner and boiler development, and recent results to evaluate critical components needed to advance its TRL.

Magalhaes, Duarte↗
DOE OSTI2014

Focal plane array with modular pixel array components for scalability

A modular, scalable focal plane array is provided as an array of integrated circuit dice, wherein each die includes a given amount of modular pixel array circuitry. The array of dice effectively multiplies the amount of modular pixel array circuitry to produce a larger pixel array without increasing die size. Desired pixel pitch across the enlarged pixel array is preserved by forming die stacks with each pixel array circuitry die stacked on a separate die that contains the corresponding signal processing circuitry. Techniques for die stack interconnections and die stack placement are implemented to ensure that the desired pixel pitch is preserved across the enlarged pixel array.

42 ENGINEERING↗
DOE OSTI2015

Modular anode assemblies and methods of using the same for electrochemical reduction

Modular anode assemblies are used in electrolytic oxide reduction systems for scalable reduced metal production via electrolysis. Assemblies include a channel frame connected to several anode rods extending into an electrolyte. An electrical system powers the rods while being insulated from the channel frame. A cooling system removes heat from anode rods and the electrical system. An anode guard attaches to the channel frame to prevent accidental electrocution or damage during handling or repositioning. Each anode rod may be divided into upper and lower sections to permit easy repair and swapping out of lower sections. The modular assemblies may have standardized components to permit placement at multiple points within a reducing system. Example methods may operate an electrolytic oxide reduction system by positioning the modular anode assemblies in the reduction system and applying electrical power to the plurality of anode assemblies.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2020

Modular In-Chamber Electron Beam Welding – Process Planning: Welding, Cladding, Inspection, and Manufacturing

Electron beam welding (EBW) is commonly employed by industry today to join relatively thin section components. Industrial sectors which utilize the technology include; automotive, aircraft, aerospace, defense, medical, oil & gas, etc. The ability to produce single pass, thick section (up to 6 inches, 150mm) welds has also been available for more than 40 years; however, the technology has not been deployed for civil nuclear manufacturing and fabrication such as reactor pressure vessels, steam generators, or pressurizers. Instead, thick section joining is performed much in the same manner it has been for decades using submerged arc or gas tungsten arc welding processes. Recent research performed under U.S. Department of Energy (DOE) project DE-NE0008629 has demonstrated that the overall welding time to produce one major reactor pressure vessel (RPV) girth weld can be reduced from weeks to less than 90 minutes, while maintaining exceptional quality and inspection characteristics. The subject project (DE-NE0008846) investigates a modular in-chamber (MIC) EBW approach which allows various RPV sections to be joined within a “modular” chamber. The MIC-EBW approach utilizes individual modules that can be stacked and de-stacked to various heights to enable production girth welds to be performed at a given elevation. This report describes the various processing methodology necessary to complete major girth weldments for the NuScale Power small modular reactor including welding development, manufacturing, production sequence, inspection, and cladding.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2021

Modular assemblies and systems for cell cultures and methods thereof

The present invention relates to modular assemblies and systems for conducting cell analyses. In particular embodiments, an assembly has micron-scale fluidic structures, thereby minimizing sample use, and possesses a modular architecture that facilitates disassembly of the apparatus. Thus, one such modular assembly facilitates on-chip cell growth and on-chip assays; and then, as needed, the assembly can be disassembled to provide direct access to the cells that were incubated and treated within the chip. Methods of making and using such assemblies, as well as systems thereof, are further described herein.

Hatch, Anson↗
DOE OSTI2023

Determining the Effects of Neutron Irradiation on the Structural Integrity of Additively Manufactured Heat Exchangers for Very Small Modular Reactor Applications, DOE Final Report (Project # 19-16980)

Auburn University (AU) teamed with the University of Missouri Research Reactor (MURR) and Kansas State University (KSU) to determine how to best use laser-powder bed fusion (L-PBF) additive manufacturing (AM) methods for generating radiation resistant nickel-based superalloys, Inconel alloy 625 and 718, for special purpose reactor (SPR) or very small modular reactor (vSMR) heat-exchangers (HeXs). Compact, conformal, and durable HeXs that are tolerant of extreme environments are needed for supporting the technical maturity of next-generation, portable compact reactors. AM is an enabler for realizing this new wave of HeXs – providing a means to make customizable hot and cold stream architectures with novel flow path geometries (e.g., tortuous channels with non-uniform, asymmetric cross-sections) and reduced layer-to-layer contact resistance (i.e., no separate bonding procedure required). AM further enables a more time/cost efficient means for fabricating SPRs by reducing the number of suppliers required for HeX assembly and allowing for on-site HeX fabrication. The project aim has been to better understand how neutron irradiation affects the microstructure and properties of additively manufactured nickel-based superalloys, to accelerate their safe, reliable use in the modular reactor industry. The major objective was to qualify/quantify the microstructure and microhardness of nickel-based superalloys (including Inconel 718 and 625) additively manufactured via the L-PBF process in the neutron-dosed (irradiated) and non-irradiated states over a course of 3 years. Effects of build orientation during L-PBF and post-AM heat treatments on neutron resistance, microstructure and mechanical properties were also investigated. Neutron damage mechanisms via hardening were characterized. This project combined subject-matter experts in AM, mechanical/microstructure metallic part characterization, and neutron irradiation, as well as unique assets and capabilities at AU and MURR at MU, to ensure project results translated to effectively addressing known gaps in nuclear science and engineering. Parts were fabricated using L-PBF systems readily available at AU. Specimens were then irradiated using MURR facilities; a manipulator equipped hot cell was also used to measure material hardness after dosing. MURR, a 10 MW, light-water nuclear reactor, is the largest, highest powered, highest-flux university owned research reactor in the U.S. The major findings in this project provide evidence that AM can serve as an alternative way to build structural components for future advanced small modular reactors using advanced materials like Inconel 625 (IN625) or Inconel 718 (IN718). After full spectrum neutron irradiation, vertically as-built AM IN625 samples were observed to display better resistance towards radiation-induced-hardening defects relative to traditionally machined metals. A Vickers microhardness tester, using settings of 1 kgf and dwell time of 15 seconds per indentation, was used to measure hardness in this study. The as-built, vertically printed samples experienced 1.2% of radiation hardening vs. 5.25% radiation hardening observed in wrought IN625. Another set of IN625 and IN718 samples were exposed to fast neutron irradiation. It was observed that IN718 showed more resistance towards radiation hardening compared to IN625 samples indicating IN718 had a better performance. Results showed that the IN718 samples experienced less change (-2.5 to 3.24 %) in microhardness. On the other hand, IN625 samples underwent more (0.9 to 7.21%) change in microhardness after fast neutron irradiation. AM IN625 samples were irradiated using an ion (proton) beam in cyclotron. The mechanical properties of AM samples post irradiation were compared with wrought samples. The irradiated region on the samples were tested using nano-hardness indention. It was observed that the beam current and time used in this study generated an annealing effect and thus reduced the hardness of the samples. The sum of the project results provide precious insight into how one may minimize radiation hardening in AM materials while maintaining material property constraints. Results should assist engineers in selecting an appropriate heat treatment for AM nickel-based superalloys for increased radiation resistance. Results should increase confidence levels for adopting AM for building nuclear reactor components which perform the same or better than conventionally manufactured components. Fast neutron irradiation testing provided an accelerated means of obtaining radiation effects without making materials radioactive and difficult to handle.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗