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DOE OSTI2026

Advancing Conduction-Cooled 650 MHz SRF Technology for Industrial Accelerators at Fermilab's IARC

The National Nuclear Security Administration (NNSA) funds the Illinois Accelerator Research Center (IARC) at Fermilab in developing a high-power, conduction-cooled Superconducting Radio Frequency (SRF) accelerator tailored for industrial applications requiring robust and efficient operation. A 650 MHz, 1.6 MeV, 20 kW SRF accelerator is currently under development, employing a conduction cooling approach to simplify cryogenic requirements and enhance accessibility for industrial use. The accelerator’s control system is implemented on the Blinky Lite platform, selected for its open-source architecture, secure remote access capabilities, and operational flexibility—attributes advantageous for industrial deployment and sustained operation. A dedicated beamline is designed to measure essential beam parameters and test the integrated performance of the accelerator and control systems, thereby validating their operational readiness for intended applications

Ji, Y. [Fermilab] (ORCID:0000000233981752)↗

DOE OSTI2021

Wind Energy Forecasting with the Weather Research and Forecasting Model

This was a collaborative effort between Lawrence Livermore National Security, LLC as manager and operator of Lawrence Livermore National Laboratory (LLNL) and Siemens Energy, Inc. (Siemens) to develop a wind resource forecasting tool. LLNL was to develop an independent high-resolution mesoscale modeling capability forecasting tool that could be implemented in conjunction with existing wind farm control and monitoring software to provide forecasting of wind resources using local observations of winds and temperature. Research with LLNL’s state-of-the-art large-eddy simulation meteorological prediction model, based on the community WRF model and innovative turbulence parameterizations, would improve that model’s applicability to large wind farms offshore and in complex terrain. The modeling capability would include uncertainty quantification. Finally, the application of the modeling tool and existing global climate change predictions would enable the delineation of the likely effects of climate change on wind resources. Siemens was to provide high time resolution hub-height wind speed and other meteorological data streams, including temperature profiles from wind farms, for LLNL to incorporate into the modeling system, to validate and tune this forecasting model for their locations of interest. These data streams would also be used for longer-term studies of correlations of wind resources to climate oscillations to indicate how long-term climate change trends may affect the available wind resource. Siemens would also provide information and observations of turbine wakes for incorporation into the modeling tool. By implementing state-of-the-art turbulence parameterizations into a simulation model and/or ensembles of simulation models, and by integrating real-time hub height wind speed and other meteorological datastreams from wind farms into that model or ensemble of models, LLNL would develop a forecasting tool that could be implemented by Siemens as an add-on to existing wind farm control and monitoring software to provide owners with useful resource forecasting. The desired outcome was that the accuracy level of the output would be sufficient to substantiate power output commitments. The final deliverable for this work would consist of a document outlining the algorithms and software tools that could be integrated into Siemens Wind Park Supervisor.

17 WIND ENERGY↗

DOE OSTI2021

Validation and Demonstration of Control System Functional Capabilities within the IES Plug-and-Play Simulation Environment

The concept of an integrated energy system (IES) is meant to combine different energy technologies in synergistic ways to achieve a more secure and economical energy supply. The RAVEN-based HYBRID framework is used to find the optimal installed capacity and the optimal economical dispatch of each component of the IES. The new RAVEN plugin for grid and capacity optimization (HERON) only addresses the limits that affect the production variables and the corresponding rates of variation (explicit constraints). However, other variables are subject to constraints, and the associated limits should be accounted for (implicit constraints). In particular, for the power dispatch problem, the optimization algorithm takes into account the limits on the electrical power output and the corresponding hourly power variations but does not consider other constraints on process variables whose response affects the service life of the IES. This report describes a scheme that allows accounting for implicit constraints without increasing the size of the optimization problem. To obtain a more accurate approximation of the nonlinear dynamic behavior, a parametric version of the dynamic mode decomposition with control (DMDc) algorithm was developed to derive the state-space representation matrices of the IES components at different scheduling parameter. Thanks to this approach, a more accurate approximation of the system response can be obtained, the limits imposed by thermal mechanical implicit constraints can be translated into power dispatch limits, and the feedbacks to HERON power dispatcher can be provided. To assess the developed methodology, a power dispatching test case composed of three power generating and storage units (Balance of Plant, Secondary Energy Source, Thermal Energy Storage) was developed. The power output of each one of the three units was optimized to meet the imposed time-dependent load demand trajectory and to maximize the IES profitability by meeting both the explicit and implicit constraints.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2021

Aerosol Chemical Speciation Monitor (ACSM) Composition-Dependent Collection Efficiency (CDCE) Value-Added Product Report

Aerosol particles influence the Earth’s radiation balance directly by absorbing and scattering light and indirectly by influencing cloud formation, properties, and lifetimes. Measurements of aerosol particle optical properties, mass loading, size distributions, microphysical properties, cloud formation properties, and chemical composition are important for understanding the aerosol life cycle and for validating earth system models that predict these quantities. The U.S. Department of Energy Atmospheric Radiation Measurement (ARM) user facility’s Aerosol Observing System (AOS) is a highly instrumented platform that measures many of these aerosol properties in situ. The Aerodyne aerosol chemical speciation monitor (ACSM) is a baseline instrument deployed in the AOS. The ACSM provides a quantitative measurement of aerosol particle chemical composition for non-refractory (operationally defined as components that evaporate on the 600ºC vaporizer) aerosol components in real time. Standard output is the mass concentration of particulate organics, nitrate, sulfate, chloride, and ammonium. One well-known limitation to the accuracy of the ACSM data is in evaluating the fraction of the ambient aerosol particles that are detected by the instrument. This quantity is referred to as the collection efficiency (CE) and is often less than unity. This is attributed to particles rebounding after impaction onto the heated vaporizer rather than being trapped, volatilized rapidly, and detected. Other factors, such as divergence of the aerosol particle beam, may also impact CE, but the particle rebound effect is the dominant factor. Scientists will sometimes assume CE = 0.5 (i.e., one half of sampled particles are detected) for ambient particles collected during field missions. However, parameterizations have been developed that express CE as a function of the measured chemical composition, referred to as the composition-dependent collection efficiency (CDCE). The physical explanation for a CDCE, supported by laboratory studies, is that rebound from the vaporizer is a function of the particle phase, with liquid-like particles “sticking” to the vaporizer and solid-like or crystalline particles “bouncing” from the vaporizer. Thus, particles with compositions are liquids-like under the measurement conditions (e.g., certain organics, acidic particles, particles enriched in nitrate) have CE close to unity while crystalline or solid particles (e.g., deliquesced ammonium sulfate) have lower CE. This value-added product (VAP) implements the procedure described by Middlebrook et al. (2012) to correct the ACSM data for the composition-dependent collection efficiency. Applying this parameterization improves the accuracy of the ACSM data and brings them into better agreement with other co-located aerosol measurements.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2021

Performance Validation of Pulsed Thermal Imaging System for In-Service Applications

Additive manufacturing (AM) is an emerging method for cost-efficient fabrication of complex topology nuclear reactor parts from high-strength corrosion resistance alloys, such as stainless steel and Inconel. AM of metallic structures for nuclear energy applications is currently based on laser powder bed fusion (LPBF) process, which has the capability of melting metallic powder and net shaping the structures with relatively high precision. Some of the challenges with using LPBF method for nuclear manufacturing include the possibility of introducing pores into metallic structures. Integrity of AM structures needs to be evaluated nondestructively because material flaws could lead to premature failures in high temperature nuclear reactor environment. Currently, there exist limited capabilities to evaluate actual AM structures non-destructively. Pulsed Thermography Imaging (PTI) provides a capability for non-destructive evaluation (NDE) of subsurface defects in arbitrary size structures. The PTI method is based on recording material surface temperature transients with infrared (IR) camera following thermal pulse delivered on material surface with flash light. The PTI method has advantages for NDE of actual AM structures because the method involves one-sided non-contact measurements and fast processing of large sample areas captured in one image. Following initial qualification of an AM component for deployment in a nuclear reactor, a PTI system can also be used for in-service nondestructive evaluation (NDE) applications. In this report, we describe recent progress in enhancing PTI capabilities in detecting microscopic defects in metallic specimens. SS316 and IN718 specimens were developed with a pattern of subsurface calibrated flat bottom hole (FBH) defects with diameters from 500µm to 200µm. FBH’s were created with EDM (electron discharge machining) drill. PTI imaging data was processed Spatial Temporal Denoised Thermal Source Separation (STDTSS) unsupervised machine learning (ML) algorithm. We show that defects as small as 200µm in SS316 and IN718 can be detected with STDTSS algorithm. To the best of our knowledge, these are the smallest detected defects which are reported in literature.

42 ENGINEERING↗

DOE OSTI2022

TA-60-0017 Operations-Based Emergency Drill Controller/Observer Briefing [Slides]

This drill is designed to give players the opportunity to practice/train on response strategies, actions, and processes for responding to a given simulated emergency at TA-60-0017 in an open, no fault environment. This drill is also an opportunity to train or practice on the use of new procedures, equipment, or systems, or validate new policies/procedures.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2022

Field Validation of a Building Operating System Platform

The U.S General Services Administration's (GSA's) Green Proving Ground program, in partnership with the National Renewable Energy Laboratory. completed a large pilot study of an Energy Management Information Systems (EMIS) with Automated System Optimization (ASO). Four test bed facilities, each with different building characteristics and systems, were chosen for the implementation of cloud-based EMIS with ASO. Depending on functionality, this tool can be extremely effective in energy management and energy optimization in buildings. The capabilities evaluated in the pilot ranged from energy savings and energy consumption predictions to evaluations of user acceptance, operability, and ease of installation. This report presents the methodology, lessons learned and best practices, and deployment recommendations for the GSA's portfolio of commercial office space, comprising more than 8,500 properties.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2022

Strain gauge for testing microreactor hexagonal core blocks in the Single Primary Heat Extraction and Removal Emulator

To support the development and deployment of microreactor technologies, experiments that help verify and validate reactor systems and components are performed at non-nuclear test facilities. The Single Primary Heat Extraction Removal Emulator at Idaho National Laboratory is one of these test facilities and was used to monitor a test article that has a prototypic geometry of a heat-pipe cooled microreactor core block. To collect crucial temperature and strain data during testing, temperature and strain sensing fiber optics were embedded to the surface of the test article using an ultrasonic additive manufacturing technique. To support and provide benchmark strain data for the embedded sensors, a commercial resistive strain gauge was attached. This report will discuss the results from the deployment of the commercial strain gauge which includes the setup/attachment strategies, data acquisition, and analysis of the strain data.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Developing machine-learning potentials to study properties of the tritium formation and diffusivity in pure and defective Zircaloy-4 getters

Objective of this work was to study the formation of Sn impurity and hydride phases in Zr and study their impacts on the diffusion kinetics of 3 H by using DFT based ML approach. By implementing deep neural potential (DNP) technique, we developed potential for Zr-H and Sn impurity systems and validated the DNP by using DFT results. We found that by implementing machine learning approach, it is possible to achieve accuracy comparable to DFT level for the more realistic models by using less computational time and resources.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Ultrasonic Measurements of Temperature Profile and Heat Fluxes in Coal-Fired Power Plants (Final Report)

Many industrial processes are inaccessible or inhospitable to characterization by traditional temperature measurement methods, such as thermocouples, especially over prolonged exposure to harsh environments. Ultrasound is an established characterization technology with diverse applications ranging from medical imaging to therapies to flaw detection to nondestructive evaluation. Ultrasound may characterize solid materials and components noninvasively as a nondestructive evaluation modality and obtain internal measurements of material properties. For example, the speed of ultrasound propagation changes with Young’s modulus and Poisson’s ratio, which can be found from its measurements. Traditional ultrasonic characterization assumes all material properties remain constant with the position. When this assumption holds, a property of interest may be measured by relating it to the speed of ultrasound propagation (or a speed of sound, SOS) and measuring the SOS by timing the ultrasound propagation through a known distance. However, when a property of interest is spatially distributed, the propagation time depends on the SOS changing with the position along the ultrasound propagation path. The multiple temperature distributions may lead to an identical time of flight (TOF). Temperature is one property that impacts the speed of ultrasound and often cannot be assumed to remain constant with the position. Previously, in the context of temperature, we addressed the challenge of ultrasonic characterization of spatially distributed properties by developing a method for measuring segmental temperature distributions (MSTD). This method divides the ultrasonic propagation into segments bound by echogenic features. These features provide ultrasonic interfaces where some energy is reflected toward the receiving transducer, and the rest continues through the medium. The time-of-flight between the echoes reflected from echogenic features characterizes the spatial distribution in the properties of interest in the corresponding segment of the ultrasonic propagation path. This project demonstrated the application of the MSTD method in industrial conditions of the coal-fired power plant. We implemented the MSTD using metals and alloys waveguides, which may be the existing structure for which the temperature distribution is characterized or purposefully designed waveguides added to the structure by welding or other means specifically to quantify thermal properties using the MSTD method. Previous iterations of the MSTD method used ceramic and cementitious waveguides, which significantly attenuate ultrasound. On the other hand, low attenuation in metallic waveguides creates interactions between echogenic features which compilates the signal analysis in the segmental TOF measurements. We have established the WG design principles that minimize the interferences between trailing and primary echoes and, in some cases, eliminate them. The waveguides in which echoes do not interfere improve the timing accuracy and the robustness of ultrasonic measurements of the spatial distributions in material properties. Our emphasis remained on the estimation of the temperature distributions. We have developed general recommendations for designing ultrasonically segmented waveguides with the reduced influence of trailing echoes. Two of our waveguide designs were tested in the industry. The first waveguide was designed for insertion into a combustion zone of the utility-scale coal-fired power plant boiler. The second design allows the characterization of temperature distribution in the direction normal to the boiler’s water wall, a large heat exchanger converting the chemical energy released during combustion to the steam driving the electrical power generation turbines. These waveguides were designed to operate within a restrictive space of thermally insulated water wall and incorporate densely located echogenic features while combatting the influence of trailing echoes. The project has successfully demonstrated the feasibility of using the developed method for accurate, continuous, and robust temperature measurements in extreme environments of power generation and other industrial processes. It, therefore, has achieved its overarching goal of advancing the technology readiness level of the novel Ultrasound Measurements of Segmental Temperature Distribution (US-MSTD) method for real-time measurements of the temperature distribution and heat fluxes closer to commercial availability, developing a prototype multipoint measurement system, and validating its performance on coal-fired utility boilers. The success of this project was achieved in collaboration with the power generator, Rocky Mountain Power, and set the stage for the transfer of this technology from the laboratory to the industry.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2023

Applicability of the Sum-of-Fractions for Moderated Systems [Slides]

This presentation is for addressing the presence of multiple fissionable nuclides in a moderated system and validation with benchmarking gaps. The presentation finds: no instances of the use of the Sum-of-Fractions (SoF) method resulted in k eff values exceeding the calculational margin, when utilizing the SoF include all fissile nuclides, provides additional flexibility than 8.15 for mixtures, extend area of applicability by extending validation.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2023

Integrated Process Testing of MSR Salt Spill Accidents

Part of the licensing process for new nuclear reactors requires vendors to assess the potential consequences of identified accident scenarios using accident progression modeling. The accident scenario that will likely be evaluated by all molten salt reactor (MSR) developers is a spill of radionuclide-bearing fuel salt onto the reactor containment floor (i.e., a salt spill accident). The development of accident progression models requires experimental data to inform which processes to incorporate, to enable the calculation of parameters to model these processes, and to validate the model predictions. The data should quantify the sensitivities of key processes (e.g., molten salt spreading, heat transfer, containment structure corrosion, radionuclide vaporization, and aerosol generation) towards the initial conditions of the spill, the ambient environment, and the features of the containment. In addition, results from integrated process tests that quantify coupled processes are required to validate systems-level models. This report documents results from integrated process tests conducted on simulated molten salt spill accidents. The generated experimental data simultaneously quantify the heat transfer behavior of the spilled salt, compositional changes to the bulk salt, and the release of surrogate fission products from the spilled salt as aerosol particles. All tests that were conducted used FLiNaK doped with surrogate fission products, and the variables that were evaluated included the initial salt temperature and the concentration of surrogate fission products present in the salt. The major accomplishments of this work include identifying surrogate fuel salt compositions that provide insight into the dispersal behavior of radionuclides of potential significance to the source term, employing previously developed methods and measurement techniques to simultaneously measure key processes, generating data on the coupled processes of molten salt heat transfer and surrogate fission product release as aerosol particles, demonstrating new test methods for real-time monitoring of the flow rate of the spill and aerosol size quantification in an argon atmosphere, and developing a mass transfer model for cesium and iodine release from molten FLiNaK to provide insight into aerosol formation by vapor condensation. The same methodology applied herein can be employed to study different salt compositions of interest to MSR developers, different environmental conditions, and other variables that are relevant to postulated accident scenarios. The insights gained from these integrated process tests conducted at a laboratory scale will be incorporated into future integral effects tests conducted at an engineering scale.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2023

Scanning Mobility Particle Sizer (SMPS)-Aerodynamic Particle Sizer (APS) Merged Size Distribution (mergedsmpsaps) Value-Added Product Report

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2025

Advancing Conduction-Cooled 650 MHZ SRF Technology for Industrial Accelerators at Fermilab S IARC

The National Nuclear Security Administration (NNSA) funds the Illinois Accelerator Research Center (IARC) at Fermilab in developing a high-power, conduction-cooled Superconducting Radio Frequency (SRF) accelerator tailored for industrial applications requiring robust and efficient operation. A 650 MHz, 1.6 MeV, 20 kW SRF accelerator is currently under development, employing a conduction cooling approach to simplify cryogenic requirements and enhance accessibility for industrial use. The accelerator's control system is implemented on the Blinky Lite platform, selected for its open-source architecture, secure remote access capabilities, and operational flexibility attributes advantageous for industrial deployment and sustained operation. A dedicated beamline is designed to measure essential beam parameters and test the integrated performance of the accelerator and control systems, thereby validating their operational readiness for intended applications.

Ji, Yichen [Fermilab]↗

DOE OSTI2026

Super Conducting REBCO Cable Wrapper

Future upgrades to CERN particle accelerator magnets require flat, high-temperature superconducting cables, created by wrapping brittle REBCO tape around a Rutherford copper core. Because current manual wrapping processes are time-consuming and prone to damaging the delicate ceramic tape, our team was tasked with automating the fabrication. We developed a modular, wrapping machine featuring adjustment for repeatable 10°to 45° wrap angles and a precise magnetic tensioning mechanism. While full-scale testing is pending final machined parts, our 3D-printed prototype successfully validates the system’s motion and sets the stage for future testing.

Gillen, Kameron [Northern Illinois U.]↗

DOE OSTI2016

Chevron Natural Gas Carbon Capture Technology Testing Project (Final Technical Report)

The objective of this project was to design, construct, commission, and operate an engineering scale post combustion carbon capture system to validate the technical maturity, operability, and scalability of Svante’s VeloxoTherm™ solid sorbent carbon capture technology under representative flue gas conditions. The project was executed at Chevron’s Kern River oil field in the San Joaquin Valley of California and evaluated carbon capture performance using slipstream flue gas from natural gas fired once through steam generators (OTSG), including indicative coal and natural gas combined cycle (NGCC) operating scenarios.

03 NATURAL GAS↗

DOE OSTI2024

The Mu2e crystal calorimeter

The Mu2e experiment at Fermilab will search for the charged-lepton flavour violating conversion of negative muons into electrons in the coulomb field of an Al nucleus, planning to reach a single event sensitivity of about $3\cdot10^{−17}$, four orders of magnitude beyond the current best limit.The conversion electron has a clear monoenergetic signature at 104.967 MeV, slightly below the muon rest mass, and will be identified by a complementary measurement carried out by a high-resolution tracker and an electromagnetic calorimeter (EMC). The calorimeter is composed of 1348 pure CsI crystals, each read by two custom UV-extended SiPMs, that are arranged in two annular disks. The EMC should achieve better than 10% energy resolution and 500 ps timing resolution for 100 MeV electrons and maintain extremely high levels of reliability and stability and in a harsh operating environment with high vacuum, 1 T B-field and radiation exposures up to 100 krad and $10^{12} \rm{n}_\rm{1MeVeq}/\rm{cm}^{2}$.The calorimeter technological choice, along with the design of the custom front-end electronics, cooling and mechanical systems were validated through an electron beam test on a large-scale 51-crystals prototype (Module-0) and extensive test campaigns that characterised and verified the performance of crystals, photodetectors, analogue and digital electronics. This included hardware stress tests and irradiation campaigns with neutrons, protons, and photons.The production and QC phases of all calorimeter components is completed apart for the digital electronics that has been revised for improving its resilience to SEU and SEL. A series of vertical slice tests with the final electronics is being carried out on the Module-0 at LNF along with the implementation and validation of the calibration procedures. The first disk has been assembled in 2022 while the second disk is under assembly at the moment of writing. Status of construction will be summarised, along with plans for commissioning and first calibration of the fully assembled disks.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2024

Bifacial Vertical Testbed and Ground Irradiance Data in Golden, Colorado

This data was collected for Tonita et al., “Vertical bifacial photovoltaic system model validation: study with field data, various orientations, and latitudes,” for validation of optical models for vertically-oriented photovoltaics under high albedo. Ground irradiance data for vertical PV arrays modeling in agrivoltaics is also provided. The dataset is provided for further use or study as open source. For any questions on the dataset, email silvana.ovaitt@nlr.gov.

14 SOLAR ENERGY↗