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DOE OSTI2014

Progress Towards Prognostic Health Management of Passive Components in Advanced Small Modular Reactors

Sustainable nuclear power to promote energy security and to reduce greenhouse gas emissions are two key national energy priorities. The development of deployable small modular reactors (SMRs) is expected to support these objectives by developing technologies that improve the reliability, sustain safety, and improve affordability of new reactors. Advanced SMRs (AdvSMRs) refer to a specific class of SMRs and are based on modularization of advanced reactor concepts. Prognostic health management (PHM) systems can benefit both the safety and economics of deploying AdvSMRs and can play an essential role in managing the inspection and maintenance of passive components in AdvSMR systems. This paper describes progress on development of a prototypic PHM system for AdvSMR passive components, with thermal creep chosen as the target degradation mechanism.

prognostics, small modular reactors, passive compo↗

DOE OSTI2014

Modular Cascaded H-Bridge Multilevel PV Inverter with Distributed MPPT for Grid-Connected Applications

This paper presents a modular cascaded H-bridge multilevel photovoltaic (PV) inverter for single- or three-phase grid-connected applications. The modular cascaded multilevel topology helps to improve the efficiency and flexibility of PV systems. To realize better utilization of PV modules and maximize the solar energy extraction, a distributed maximum power point tracking (MPPT) control scheme is applied to both single-phase and three-phase multilevel inverters, which allows the independent control of each dc-link voltage. For three-phase grid-connected applications, PV mismatches may introduce unbalanced supplied power, leading to unbalanced grid current. To solve this issue, a control scheme with modulation compensation is also proposed. An experimental three-phase 7-level cascaded H-bridge inverter has been built utilizing 9 H-bridge modules (3 modules per phase). Each H-bridge module is connected to a 185 W solar panel. Simulation and experimental results are presented to verify the feasibility of the proposed approach.

14 SOLAR ENERGY↗

DOE OSTI2016

Crystal structure of modular sodium-rich and low-iron eudialyte from Lovozero alkaline massif

The structure of the sodium-rich representative of the eudialyte group found by A.P. Khomyakov at the Lovozero massif (Kola Peninsula) is studied by X-ray diffraction. The trigonal cell parameters are: a = 14.2032(1) and c = 60.612(1) Å, V = 10589.13 Å3, space group R3m. The structure is refined to the final R = 5.0% in the anisotropic approximation of atomic displacement parameters using 3742|F| > 3σ(F). The idealized formula (Z = 3) is Na{sub 37}Ca{sub 10}Mn{sub 2}FeZr{sub 6}Si{sub 50}(Ti, Nb){sub 2}O{sub 144}(OH){sub 5}Cl{sub 3} · H{sub 2}O. Like other 24-layer minerals of the eudialyte group, this mineral has a modular structure. Its structure contains two modules, namely, “alluaivite” (with an admixture of “eudialyte”) and “kentbrooksite,” called according to the main structural fragments of alluaivite, eudialyte, and kentbrooksite. The mineral found at the Lovozero alkaline massif shows some chemical and symmetry-structural distinctions from the close-in-composition labyrinthite modular mineral from the Khibiny massif. The difference between the minerals stems from different geochemical conditions of mineral formation in the two regions.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗

DOE OSTI2017

Modular pathway engineering for the microbial production of branched-chain fatty alcohols

The intrinsic structural properties of branched long-chain fatty alcohols (BLFLs) in the range of C12 to C18 make them more suitable as diesel fuel replacements and for other industrial applications than their straight-chain counterparts. While microbial production of straight long-chain fatty alcohols has been achieved, biosynthesis of BLFLs has never been reported. In this work, we engineered four different biosynthetic pathways in Escherichia coli to produce BLFLs. We then employed a modular engineering approach to optimize the supply of α-keto acid precursors and produced either odd-chain or even-chain BLFLs with high selectivity, reaching 70 and 75% of total fatty alcohols, respectively. The acyl-ACP and alcohol-producing modules were also extensively optimized to balance enzyme expression level and ratio, resulting in a 6.5-fold improvement in BLFL titers. The best performing strain overexpressed 14 genes from 6 engineered operons and produced 350 mg/L of BLFLs in fed-batch fermenter. The modular engineering strategy successfully facilitated microbial production of BLFLs and allowed us to quickly optimize new BLFL pathway with high titers and product specificity. More generally, this work provides pathways and knowledge for the production of BLFLs and BLFL-related, industry-relevant chemicals in high titers and yields.

09 BIOMASS FUELS↗

DOE OSTI2013

Site Suitability and Hazard Assessment Guide for Small Modular Reactors

Commercial nuclear reactor projects in the U.S. have traditionally employed large light water reactors (LWR) to generate regional supplies of electricity. Although large LWRs have consistently dominated commercial nuclear markets both domestically and abroad, the concept of small modular reactors (SMRs) capable of producing between 30 MW(t) and 900 MW(t) to generating steam for electricity is not new. Nor is the idea of locating small nuclear reactors in close proximity to and in physical connection with industrial processes to provide a long-term source of thermal energy. Growing problems associated continued use of fossil fuels and enhancements in efficiency and safety because of recent advancements in reactor technology suggest that the likelihood of near-term SMR technology(s) deployment at multiple locations within the United States is growing. Many different types of SMR technology are viable for siting in the domestic commercial energy market. However, the potential application of a particular proprietary SMR design will vary according to the target heat end-use application and the site upon which it is proposed to be located. Reactor heat applications most commonly referenced in connection with the SMR market include electric power production, district heating, desalinization, and the supply of thermal energy to various processes that require high temperature over long time periods, or a combination thereof. Indeed, the modular construction, reliability and long operational life purported to be associated with some SMR concepts now being discussed may offer flexibility and benefits no other technology can offer. Effective siting is one of the many early challenges that face a proposed SMR installation project. Site-specific factors dealing with support to facility construction and operation, risks to the plant and the surrounding area, and the consequences subsequent to those risks must be fully identified, analyzed, and possibly mitigated before a license will be granted to construct and operate a nuclear facility. Examples of significant site-related concerns include area geotechnical and geological hazard properties, local climatology and meteorology, water resource availability, the vulnerability of surrounding populations and the environmental to adverse effects in the unlikely event of radionuclide release, the socioeconomic impacts of SMR plant installation and the effects it has on aesthetics, proximity to energy use customers, the topography and area infrastructure that affect plant constructability and security, and concerns related to the transport, installation, operation and decommissioning of major plant components.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2014

Development of the Mathematics of Learning Curve Models for Evaluating Small Modular Reactor Economics

The cost of nuclear power is a straightforward yet complicated topic. It is straightforward in that the cost of nuclear power is a function of the cost to build the nuclear power plant, the cost to operate and maintain it, and the cost to provide fuel for it. It is complicated in that some of those costs are not necessarily known, introducing uncertainty into the analysis. For large light water reactor (LWR)-based nuclear power plants, the uncertainty is mainly contained within the cost of construction. The typical costs of operations and maintenance (O&M), as well as fuel, are well known based on the current fleet of LWRs. However, the last currently operating reactor to come online was Watts Bar 1 in May 1996; thus, the expected construction costs for gigawatt (GW)-class reactors in the United States are based on information nearly two decades old. Extrapolating construction, O&M, and fuel costs from GW-class LWRs to LWR-based small modular reactors (SMRs) introduces even more complication. The per-installed-kilowatt construction costs for SMRs are likely to be higher than those for the GW-class reactors based on the property of the economy of scale. Generally speaking, the economy of scale is the tendency for overall costs to increase slower than the overall production capacity. For power plants, this means that doubling the power production capacity would be expected to cost less than twice as much. Applying this property in the opposite direction, halving the power production capacity would be expected to cost more than half as much. This can potentially make the SMRs less competitive in the electricity market against the GW-class reactors, as well as against other power sources such as natural gas and subsidized renewables. One factor that can potentially aid the SMRs in achieving economic competitiveness is an economy of numbers, as opposed to the economy of scale, associated with learning curves. The basic concept of the learning curve is that the more a new process is repeated, the more efficient the process can be made. Assuming that efficiency directly relates to cost means that the more a new process is repeated successfully and efficiently, the less costly the process can be made. This factor ties directly into the factory fabrication and modularization aspect of the SMR paradigm—manufacturing serial, standardized, identical components for use in nuclear power plants can allow the SMR industry to use the learning curves to predict and optimize deployment costs.

small modular reactors (SMRs)↗

DOE OSTI2017

Advance High Temperature Inspection Capabilities for Small Modular Reactors: Part 1 - Ultrasonics

The project objective was to investigate the development non-destructive evaluation techniques for advanced small modular reactors (aSMR), where the research sought to provide key enabling inspection technologies needed to support the design and maintenance of reactor component performance. The project tasks for the development of inspection techniques to be applied to small modular reactor are being addressed through two related activities. The first is focused on high temperature ultrasonic transducers development (this report Part 1) and the second is focused on an advanced eddy current inspection capability (Part 2). For both inspection techniques the primary aim is to develop in-service inspection techniques that can be carried out under standby condition in a fast reactor at a temperature of approximately 250°C in the presence of liquid sodium. The piezoelectric material and the bonding between layers have been recognized as key factors fundamental for development of robust ultrasonic transducers. Dielectric constant characterization of bismuth scantanate-lead titanate ((1-x)BiScO 3 -xPbTiO 3 ) (BS-PT) has shown a high Curie temperature in excess of 450°C , suitable for hot stand-by inspection in liquid metal reactors. High temperature pulse-echo contact measurements have been performed with BS-PT bonded to 12.5 mm thick 1018-low carbon steel plate from 20C up to 260 C. High temperature air-backed immersion transducers have been developed with BS-PT, high temperature epoxy and quarter wavlength nickel plate, needed for wetting ability in liquid sodium. Ultrasonic immersion measurements have been performed in water up to 92C and in silicone oil up to 140C. Physics based models have been validated with room temperature experimental data with benchmark artifical defects.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2018

Advanced I&C for Fault-Tolerant Supervisory Control of Small Modular Reactors

In this research, we have developed a supervisory control approach to enable automated control of SMRs. By design the supervisory control system has an hierarchical, interconnected, adaptive control architecture. A considerable advantage to this architecture is that it allows subsystems to communicate at different/finer granularity, facilitates monitoring of process at the modular and plant levels, and enables supervisory control. We have investigated the deployment of automation, monitoring, and data collection technologies to enable operation of multiple SMRs. Each unit's controller collects and transfers information from local loops and optimize that unit’s parameters. Information is passed from the each SMR unit controller to the supervisory controller, which supervises the actions of SMR units and manage plant processes. The information processed at the supervisory level will provide operators the necessary information needed for reactor, unit, and plant operation. In conjunction with the supervisory effort, we have investigated techniques for fault-tolerant networks, over which information is transmitted between local loops and the supervisory controller to maintain a safe level of operational normalcy in the presence of anomalies. The fault-tolerance of the supervisory control architecture, the network that supports it, and the impact of fault-tolerance on multi-unit SMR plant control has been a second focus of this research. To this end, we have investigated the deployment of advanced automation, monitoring, and data collection and communications technologies to enable operation of multiple SMRs. We have created a fault-tolerant multi-unit SMR supervisory controller that collects and transfers information from local loops, supervise their actions, and adaptively optimize the controller parameters. The goal of this research has been to develop the methodologies and procedures for fault-tolerant supervisory control of small modular reactors. To achieve this goal, we have identified the following objectives. These objective are an ordered approach to the research: I) Development of a supervisory digital I&C system II) Fault-tolerance of the supervisory control architecture III) Automated decision making and online monitoring.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2024

Prefabricated Zero Ascend Omnispecies (ZAO) Modular Fish Passage Modules Using Advanced Manufacturing Techniques

The Zero Ascend Omnispecies (ZAO) fish passage attraction module “ZAO Attractor” is a novel system designed to facilitate upstream passage for a broad spectrum of fish species, with a particular focus on American shad and river herring (alewife and/or blueback herring). Combining the use of prefabricated, modular components with advanced manufacturing, the ZAO aims to provide a cost-effective and scalable solution for fish passage attractions across various hydropower sites. The system features a surface level entry, so fish do not need to climb. In addition, it is designed to be adjusted and repositioned to create the most effective attraction flows by managing the outflows from hydropower turbines. Budget Period 1 (BP1) focused on the design and modeling of the ZAO Attractor and demonstrated the engineering feasibility of a modular, prefabricated, hydrodynamically efficient structure with surface level entry and passage. It was discovered that there were limited published studies on the direct correlation between quantified flow patterns and fish attraction, emphasizing the need for controlled studies to observe and measure these effects. In Budget Period 2 (BP2), controlled studies with live fish were prioritized to address these complexities. In conclusion, the ZAO fish passage attraction module presents a promising approach to fish passage at hydropower stations, with the potential to balance environmental concerns with renewable energy development. However, further field validation and optimization are necessary to ensure its effectiveness and practicality in real-world applications.

13 HYDRO ENERGY↗

DOE OSTI2019

Economic Optimization of the Modular Structure of Complex Objects

In the design of complex objects, modular principles are of great interest. That approach has both negative and positive consequences. It clearly affects the cost of acquiring the required stock of equipment and, in particular, the spare parts necessary for its maintenance. Optimization of the modular structure of industrial equipment may best be approached in economic terms. Smart information systems for the support of management decisions prove very useful. A structure is proposed for such a system. Examples of such optimization in the aviation industry are presented, and practical experience is noted.

42 ENGINEERING↗

DOE OSTI2013

Incorporating Equipment Condition Assessment in Risk Monitors for Advanced Small Modular Reactors

Advanced small modular reactors (aSMRs) can complement the current fleet of large light-water reactors in the USA for baseload and peak demand power production and process heat applications (e.g., water desalination, shale oil extraction, hydrogen production). The day-to-day costs of aSMRs are expected to be dominated by operations and maintenance (O&M); however, the effect of diverse operating missions and unit modularity on O&M is not fully understood. These costs could potentially be reduced by optimized scheduling, with risk-informed scheduling of maintenance, repair, and replacement of equipment. Currently, most nuclear power plants have a “living” probabilistic risk assessment (PRA), which reflects the as-operated, as-modified plant and combine event probabilities with population-based probability of failure (POF) for key components. “Risk monitors” extend the PRA by incorporating the actual and dynamic plant configuration (equipment availability, operating regime, environmental conditions, etc.) into risk assessment. In fact, PRAs are more integrated into plant management in today’s nuclear power plants than at any other time in the history of nuclear power. However, population-based POF curves are still used to populate fault trees; this approach neglects the time-varying condition of equipment that is relied on during standard and non-standard configurations. Equipment condition monitoring techniques can be used to estimate the component POF. Incorporating this unit-specific estimate of POF in the risk monitor can provide a more accurate estimate of risk in different operating and maintenance configurations. This enhanced risk assessment will be especially important for aSMRs that have advanced component designs, which don’t have an available operating history to draw from, and often use passive design features, which present challenges to PRA. This paper presents the requirements and technical gaps for developing a framework to integrate unit-specific estimates of POF into risk monitors, resulting in enhanced risk monitors that support optimized operation and maintenance of aSMRs.

Advanced Small Modular Reactors↗

DOE OSTI2012

Human Reliability Analysis for Small Modular Reactors

Because no human reliability analysis (HRA) method was specifically developed for small modular reactors (SMRs), the application of any current HRA method to SMRs represents tradeoffs. A first- generation HRA method like THERP provides clearly defined activity types, but these activity types do not map to the human-system interface or concept of operations confronting SMR operators. A second- generation HRA method like ATHEANA is flexible enough to be used for SMR applications, but there is currently insufficient guidance for the analyst, requiring considerably more first-of-a-kind analyses and extensive SMR expertise in order to complete a quality HRA. Although no current HRA method is optimized to SMRs, it is possible to use existing HRA methods to identify errors, incorporate them as human failure events in the probabilistic risk assessment (PRA), and quantify them. In this paper, we provided preliminary guidance to assist the human reliability analyst and reviewer in understanding how to apply current HRA methods to the domain of SMRs. While it is possible to perform a satisfactory HRA using existing HRA methods, ultimately it is desirable to formally incorporate SMR considerations into the methods. This may require the development of new HRA methods. More practicably, existing methods need to be adapted to incorporate SMRs. Such adaptations may take the form of guidance on the complex mapping between conventional light water reactors and small modular reactors. While many behaviors and activities are shared between current plants and SMRs, the methods must adapt if they are to perform a valid and accurate analysis of plant personnel performance in SMRs.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2013

Prognostics Health Management for Advanced Small Modular Reactor Passive Components

In the United States, sustainable nuclear power to promote energy security is a key national energy priority. Advanced small modular reactors (AdvSMR), which are based on modularization of advanced reactor concepts using non-light-water reactor (LWR) coolants such as liquid metal, helium, or liquid salt may provide a longer-term alternative to more conventional LWR-based concepts. The economics of AdvSMRs will be impacted by the reduced economy-of-scale savings when compared to traditional LWRs and the controllable day-to-day costs of AdvSMRs are expected to be dominated by operations and maintenance costs. Therefore, achieving the full benefits of AdvSMR deployment requires a new paradigm for plant design and management. In this context, prognostic health management of passive components in AdvSMRs can play a key role in enabling the economic deployment of AdvSMRs. In this paper, the background of AdvSMRs is discussed from which requirements for PHM systems are derived. The particle filter technique is proposed as a prognostics framework for AdvSMR passive components and the suitability of the particle filter technique is illustrated by using it to forecast thermal creep degradation using a physics-of-failure model and based on a combination of types of measurements conceived for passive AdvSMR components.

passive components↗

DOE OSTI2014

Modular Approach for Continuous Cell-Level Balancing to Improve Performance of Large Battery Packs: Preprint

Energy storage systems require battery cell balancing circuits to avoid divergence of cell state of charge (SOC). A modular approach based on distributed continuous cell-level control is presented that extends the balancing function to higher level pack performance objectives such as improving power capability and increasing pack lifetime. This is achieved by adding DC-DC converters in parallel with cells and using state estimation and control to autonomously bias individual cell SOC and SOC range, forcing healthier cells to be cycled deeper than weaker cells. The result is a pack with improved degradation characteristics and extended lifetime. The modular architecture and control concepts are developed and hardware results are demonstrated for a 91.2-Wh battery pack consisting of four series Li-ion battery cells and four dual active bridge (DAB) bypass DC-DC converters.

25 ENERGY STORAGE↗

DOE OSTI2013

Health Monitoring to Support Advanced Small Modular Reactors

Advanced small modular reactors (aSMRs) are based on advanced reactor concepts, some of which were promoted by the Generation IV International Forum, and are being considered for diverse missions including desalination of water, production of hydrogen, etc. While the existing fleet of commercial nuclear reactors provides baseload electricity, it is conceivable that aSMRs could be implemented for both baseload and load following applications. The effect of diverse operating missions and unit modularity on plant operations and maintenance (O&M) is not fully understood and limiting these costs will be essential to successful deployment of aSMRs. Integrated health monitoring concepts are proposed to support the safe and affordable operation of aSMRs over their lifetime by enabling management of significant in-vessel and in-containment active and passive components.

Advanced Small Modular Reactors↗

DOE OSTI2021

The Fast Modular Reactor (FMR) - Development Plan of a New 50 MWe Gas-cooled Fast Reactor

General Atomics Electromagnetic Systems (GA-EMS) will be developing a new 50-megawatt electric (MWe) fast modular reactor (FMR), under the Department of Energy’s (DOE’s) Advanced Reactor Demonstration Program (ARDP), Advanced Reactor Concepts 2020 (ARC-20) development pathway, that provides safe, carbon free electricity, capable of incremental capacity additions. A modular design allows it to be factory-built and assembled on-site to keep the cost of capital low, while the dry-cooling facilitates siting to complement renewables in nearly any location. GA-EMS is committed to commercialization of the proposed reactor, with a demonstration by 2030, and deployment by the mid-2030s. The ultimate goal of the design is to develop flexible and dispatchable carbon-free power source for the 2035 US electricity market. The GAEMS- led team will verify that simplified characteristics (e.g., inert helium gas coolant, pellet-loaded fuel rod, installation-free of heat sink requirements, small and passive heat removal systems) of the FMR will result in a safe, maintainable, cost-effective, distributed, nuclear energygenerating station. Three key specific project objectives for the next three years include: Development of the conceptual design of the 50- MWe FMR plant, Achievement of Technology Readiness Level (TRL) 4 for key system and component technologies through in-pile tests, out-of-pile tests, and numerical experiments; and Development of robust techno-economic analysis (TEA) and pre-application licensing approach necessary for timely demonstration and eventual commercialization.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2022

A Scalable Method for Decarbonizing Modular Building Solutions: Preprint

The decarbonization movement emphasizes the shift in focus from energy efficiency to directly reducing global-warming impact. Blokable, LLC, a vertically integrated modular builder with an all-electric portfolio, worked with NREL on a roadmap to decarbonize its high-performance building product at a relative cost advantage by utilizing the learning curves of mass production. Previous decarbonization literature focused on either i) lifecycle assessments, or ii) efficiency measures. These decarbonization exercises were bespoke to individual building projects and did not consider positive feedback loops of builder experience or process repetition. Vertically integrated, prefab builders possess the unique ability to leverage learning and repetition to decarbonize their design-build-operate process. This collaboration between Blokable and NREL resulted in a decarbonization strategy utilizing the company's scaling and production efficiencies, on-site renewable energy and storage, and the projected evolution of building components over time based on trends and emerging legislation. The method developed here encompasses a growing business model, lifecycle carbon assessment, and projected changes in product and grid emissions over time due to existing trends and emerging legislation. This methodology incorporates learning-curve efficiencies gleaned from scaled manufacturing, as well as open-source tools integration for energy and carbon accounting. The output projects and compares cost and carbon savings per modular unit as production increases to 10,000 dwelling units annually over 15 years. The resulting roadmap illustrates a path to roughly 60% carbon savings and beyond-net-zero-energy performance at no incremental cost by 2030. The methodology can be mapped to other integrated or productized builders for methodical decarbonization.

affordable housing↗

DOE OSTI2022

A Scalable Method for Decarbonizing Modular Building Solutions

affordable housing↗