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At least 253 records · Page 14
All sourcesNASA NTRSDOE OSTI
NASA NTRSDate not supplied

System Modeling of a Lunar Molten Regolith Electrolysis Plant

Introduction: In-Situ Resource Utilization (ISRU) is the process of extracting local resources to produce commodities for propulsion, life support systems, and off-planet construction rather than transporting consumables from Earth. Molten Regolith Electrolysis (MRE) is a novel ISRU method of extracting oxygen gas and metal alloy from lunar regolith. The MRE process involves placing lunar regolith between two electrodes, through which current is passed, to melt the regolith and reduce the metal oxide constituents by direct electrolysis (e.g. FeO, SiO2, MgO, Al2O3) into oxygen gas and metal alloys. The oxygen is liquefied and used as propellant for landers, while the metals (e.g. Ferro-alloys) are further processed and used in structural building materials and parts manufacturing. A system model was developed that accounted for the major processes of an MRE plant (from excavation of raw materials to storage of products) to assess the feasibility of a lunar MRE plant. The System Engineering and Integration (SE&I) ISRU Modeling and Analysis (SIMA) team utilized its previously documented system sizing model, the Mission Analysis and Integration Tool (MAIT) [1] as framework of the system model. MAIT uses MATLAB/Simulink to integrate subsystem models into a complete system model of the MRE plant. Total mass, volume, and power requirements were computed for numerous iterations of a MRE plant. System Model: Figure 1: MRE Plant Block Diagram The regolith excavation model determines the mass and power needed to excavate sufficient regolith. The preheating auger initiates the regolith heating process before regolith enters the MRE re-actor to reduce the energy required to turn the solid into a molten liquid. The MRE reactor is modeled in COMSOL Multiphysics and based on the research by Dominguez, Sibille, and Schreiner [2, 3, 4]. This preliminary reactor model provides an accurate calculation of thermal equilibrium during electrochemical operation of the reactor system to assess the optimal mass and power required to process the inlet flow of regolith. The model also computes the outlet flowrates of oxygen and molten products. For this analysis, the primary components of the metal alloy considered were iron and silicon. The oxygen is then purified using an Yttrium Stabilized Zirconia (YSZ) electrode, followed by liquefaction using a 90K cryocooler to be stored as liquid oxygen in insulated cylindrical tanks. In future iterations of the system model, the molten metal tapped from the MRE reactor will undergo additional processing or refinement. However, downstream handling of metals is currently a technology gap that is missing a high TRL subsystem model. Therefore, for this analysis, the accumulated metal alloy stream terminates after leaving the MRE reactor. Study Goals: This analysis investigates multiple input variables to the system to determine the sensitivity of a (near) complete plant at full-scale. This preliminary investigation ran parametric sweeps on the MRE reactor geometry, electrical current supply, layers of multi-layer insulation (MLI) on the reactor, size of the electrodes in the oxygen purification model, and regolith composition (based on landing site location). Three production targets of oxygen (1,000, 10,000, and 50,000 kg/yr) were investigated for this analysis. The parametric sweeps conducted in this analysis provide valuable insight into the expected impact of the various model inputs on plant size. This information can be used to identify the most critical components of the plant and guide future decisions on allocating funding for research and development, providing subsystem developers with appropriate interfaces with downstream and upstream processes, and assessing the overall feasibility of MRE when compared to other ISRU plants. References: [1] Carlson, A. et al. (2024) ICES, ICES-2024-53. [2] Dominguez, D.A., and Sibille, L. (2011) AIAA, AIAA-2011-700. [3] Schreiner, S.S. (2015) MIT, Dissertation. [4] Schreiner, S.S. et al. (2016) ASR, 57(7), pp.1585-1603.

ISRU↗
DOE OSTI2025

INL_intern_poster_RashedA

Advanced nuclear reactors often operate at elevated temperatures, novel fuel with different chemical and thermal properties that may interact differently with cladding, new coolants (e.g., molten salt, liquid metal, or sodium) that are chemically aggressive, requires cladding materials with superior oxidation, corrosion, and creep resistance. Developing fuel cladding for advanced reactors is essential, as the cladding plays a critical role in reactor safety, performance, and longevity. In this study, innovative Non-Concentrated Alloys (NCAs) were developed as novel fuel cladding materials for advanced nuclear reactors. Multiple elements were chosen for the alloys. NCAs were manufactured and tested mechanically, showing promise with the arc-melting method, and setting a clear path for the next step of NCAs' development as a fuel cladding for advanced nuclear reactors.

36 - MATERIALS SCIENCE↗
DOE OSTI2024

MARVEL Corrosion Test Interim Report

This study explores eutectic gallium-indium-tin (e-GaInSn) as a potential coolant for the intermediate heat exchanger for the MARVEL microreactor. E-GaInSn has an exceptionally low melting point of 10.8 °C and a high boiling point exceeding 1300 °C [4]. This wide temperature range provides designers with a significant margin to coolant boiling, even under severe accident conditions. Moreover, e-GaInSn is highly stable in both air and water demonstrating a high coefficient of thermal conductivity compared to conventional coolants like water or polymer-based solutions, along with a large heat capacity and low vapor pressure [5, 6]. While its heat transfer characteristics may not match those of some other liquid metals such as sodium, they are still quite favorable [6]. More importantly, gallium does not present issues related to chemical activity in a nuclear reactor environment. These unique and advantageous properties make e-GaInSn an attractive option for reactor applications. However, it is essential to thoroughly evaluate the compatibility of E-GaInSn with structural materials, particularly steels, for which it has a relatively high affinity. Presently, the compatibility data for these liquid metals or alloys with candidate structural materials remains limited, underscoring the need for further research to ascertain their suitability as liquid breeders or coolants [7

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS2004

Spatial Distributions of Metal Atoms During Carbon SWNTs Formation: Measurements and Modelling

Experiments and modelling have been undertaken to clarify the role of metal catalysts during single-wall carbon nanotube formation. For instance, we wonder whether the metal catalyst is active as an atom, a cluster, a liquid or solid nanoparticle [1]. A reactor has been developed for synthesis by continuous CO2-laser vaporisation of a carbon-nickel-cobalt target in laminar helium flow. The laser induced fluorescence technique [2] is applied for local probing of gaseous Ni, Co and CZ species throughout the hot carbon flow of the target heated up to 3500 K. A rapid depletion of C2 in contrast to the spatial extent of metal atoms is observed in the plume (Fig. 1). This asserts that C2 condenses earlier than Ni and Co atoms.[3, 4]. The depletion is even faster when catalysts are present. It may indicate that an interaction between metal atoms and carbon dimers takes place in the gas as soon as they are expelled from the target surface. Two methods of modelling are used: a spatially I-D calculation developed originally for the arc process [5], and a zero-D time dependent calculation, solving the chemical kinetics along the streamlines [6]. The latter includes Ni cluster formation. The peak of C2 density is calculated close to the target surface where the temperature is the highest. In the hot region, C; is dominant. As the carbon products move away from the target and mix with the ambient helium, they recombine into larger clusters, as demonstrated by the peak of C5 density around 1 mm. The profile of Ni-atom density compares fairly well with the measured one (Fig. 2). The early increase is due to the drop of temperature, and the final decrease beyond 6 mm results from Ni cluster formation at the eutectic temperature (approx.1600 K).

Cau, M.↗
DOE OSTI2021

Lithium, a path to make fusion energy affordable

In this tutorial article, we review the technological, physics, and economic basis for a magnetic fusion device utilizing a flowing liquid lithium divertor (molten metal velocity in the range of cm/s) and operating in a low-recycling plasma regime. When extrapolated to magnetic fusion reactor scale, the observed effects of a liquid lithium boundary on recycling reduction, confinement increase, and anomalous heat transport mitigation may offer a fundamentally distinct and promising alternative route to fusion energy production. In addition, this lithium-driven low recycling regime could accelerate fusion’s commercial viability since such a device would be smaller, dramatically decreasing plant and electricity costs if all technological complexities are solved. First, the theoretical basis of the energy confinement and fusion performance as well as the related possibilities of low recycling regimes driven by flowing lithium plasma-facing components are reviewed. Then the paper emphasizes the technological obstacles that need to be overcome for developing the necessary systems for such a flowing liquid lithium solution at reactor scale and details how many of these have been overcome at laboratory and/or proof-of-concept scale. Finally, the current and planned scientific and engineering endeavors being performed at the University of Illinois at Urbana-Champaign regarding this alternative reactor option are discussed.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS2005

Closed-Cycle Engine Program Used to Study Brayton Power Conversion

One form of power conversion under consideration in NASA Glenn Research Center's Thermal Energy Conversion Branch is the closed-Brayton-cycle engine. In the tens-of-kilowatts to multimegawatt class, the Brayton engine lends itself to potential space nuclear power applications such as electric propulsion or surface power. The Thermal Energy Conversion Branch has most recently concentrated its Brayton studies on electric propulsion for Prometheus. One piece of software used for evaluating such designs over a limited tradeoff space has been the Closed Cycle Engine Program (CCEP). The CCEP originated in the mid-1980s from a Fortran aircraft engine code known as the Navy/NASA Engine Program (NNEP). Components such as a solar collector, heat exchangers, ducting, a pumped-loop radiator, a nuclear heat source, and radial turbomachinery were added to NNEP, transforming it into a high-fidelity design and performance tool for closed-Brayton-cycle power conversion and heat rejection. CCEP was used in the 1990s in conjunction with the Solar Dynamic Ground Test Demonstration conducted at Glenn. Over the past year, updates were made to CCEP to adapt it for an electric propulsion application. The pumped-loop radiator coolant can now be n-heptane, water, or sodium-potassium (NaK); liquid-metal pump design tables were added to accommodate the NaK fluid. For the reactor and shield, a user can now elect to calculate a higher fidelity mass estimate. In addition, helium-xenon working-fluid properties were recalculated and updated.

Johnson, Paul K.↗
DOE OSTI2021

Effects of Radiation-Induced Defects on Corrosion

The next generation of nuclear reactors will expose materials to conditions that, in some cases, are even more extreme than those in current fission reactors, inevitably leading to new materials science challenges. Radiation-induced damage and corrosion are two key phenomena that must be understood both independently and synergistically, but their interactions are often convoluted. In the light water reactor community, a tremendous amount of work has been done to illuminate irradiation-corrosion effects, and similar efforts are under way for heavy liquid metal and molten salt environments. While certain effects, such as radiolysis and irradiation-assisted stress corrosion cracking, are reasonably well established, the basic science of how irradiation-induced defects in the base material and the corrosion layer influence the corrosion process still presents many unanswered questions. In this review, we summarize the work that has been done to understand these coupled extremes, highlight the complex nature of this problem, and identify key knowledge gaps.

36 MATERIALS SCIENCE↗
NASA NTRS1986

Modeling of transient heat pipe operation

Mathematical models and associated solution procedures which can be used to design heat pipe cooled structures for use on hypersonic vehicles are being developed. The models should also have the capability to predict off-design performance for a variety of operating conditions. It is expected that the resulting models can be used to predict startup behavior of liquid metal heat pipes to be used in reentry vehicles, hypersonic aircraft, and space nuclear reactors. Work to date related to numerical solutions of governing differential equations for the outer shell and the combination capillary structure and working fluid is summarized. Finite element numerical equations using both implicit, explicit, and combination methods were examined.

Colwell, G. T.↗
NASA NTRS1950

Preliminary analysis of three cycles for nuclear propulsion of aircraft

A preliminary study was made of the feasibility of three cycles for nuclear propulsion of aircraft: a direct-air-turbojet, a binary liquid-metal turbojet, and a helium compressor jet. All three cycles appeared feasible for flight at a Mach number of 0.9 and altitudes up to 50,000 feet; the liquid-metal cycle appeared feasible for flight at a Mach number of 1.5. The air and helium cycles resulted in heavier aircraft than did the liquid-metal cycle, particularly at a Mach number of 1.5. The relative advantage of the liquid-metal cycle became greater as the flight speed and altitude increased, and as the reactor wall temperature decreased.

Humble, L V↗
DOE OSTI2022

Eddy Current Flow Meter Measurements and Modeling Validation

The goal of the eddy current flow meter (ECFM) is to monitor velocities and temperatures of conductive liquid metals. The ECFM can also detect voids in two-phase liquid metal flows. Measurement of these flows can greatly improve the accuracy of the empirical formulas used for fluid dynamics near the reactor core and aid in mapping any non-uniformities in fluid flow such as estimates of temperature and phase. While the eventual goal is to develop the ECFM for the liquid sodium surrounding the Versatile Test Reactor (VTR) core, this report focuses on modeling and experimental validation of ECFM for a moving solid test rod and for liquid mercury in the Target Test Facility (TTF) flow loop to better understand and further develop ECFM measurement capabilities by validating model predictions with benchmark experiments. Eventually the models could be used to design and optimize future ECFMs for specific applications such as monitoring flow within the VTR pool.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Plutonium-238 Production Program Results, Implications, and Projections from Irradiation and Examination of Initial NpO 2 Test Targets for Improved Production

An alternative target design with potential improvements, including a major increase in 238 Pu production rate and annual capacity; fewer targets to be fabricated, irradiated, and processed; and a significant replacement of a large volume of caustic-nitrate, aluminum-bearing radioactive liquid waste with a smaller volume of solid metal waste, has been conceived and evaluated using reactor physics and thermal-hydraulic analyses. The alternative target design uses pressed pellets of 237 NpO 2 , sintered to 92% to 93% of theoretical density, and stacked inside a Zircaloy-4 cladding tube. Additionally, four test targets were fabricated, irradiated, and examined. No melting or other potential problems were indicated. Projections from measured constituents indicated annual production could be increased by a factor of ~2, and the number of targets required to be fabricated, irradiated, and processed could be reduced by a factor of ~5.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS2011

Online Oxide Contamination Measurement and Purification Demonstration

Liquid metal sodium-potassium (NaK) has advantageous thermodynamic properties indicating its use as a fission reactor coolant for a surface (lunar, martian) power system. A major area of concern for fission reactor cooling systems is system corrosion due to oxygen contaminants at the high operating temperatures experienced. A small-scale, approximately 4-L capacity, simulated fission reactor cooling system employing NaK as a coolant was fabricated and tested with the goal of demonstrating a noninvasive oxygen detection and purification system. In order to generate prototypical conditions in the simulated cooling system, several system components were designed, fabricated, and tested. These major components were a fully-sealed, magnetically-coupled mechanical NaK pump, a graphite element heated reservoir, a plugging indicator system, and a cold trap. All system components were successfully demonstrated at a maximum system flow rate of approximately 150 cc/s at temperatures up to 550 C. Coolant purification was accomplished using a cold trap before and after plugging operations which showed a relative reduction in oxygen content.

Bradley, D. E.↗
DOE OSTI2025

Multiphase Species Transport Modeling for Molten Salt Reactors in the System Analysis Module: Generation, Decay, Deposition, and Extraction of Insoluble Fission Products

With the increase of interests in the design and deployment of advanced reactor systems, a desire for simulation tools supporting system analysis of reactor operation and safety is rising. Molten salt reactors (MSRs), one of the advanced reactor systems, utilize liquid fused salt fuel as both coolant and fuel. During operation, MSR generates insoluble fission products, including noble metals and gases. The buildup of these species in fuel salt presents safety concerns as they may deposit on surfaces of critical components and produce excessive decay heat, causing the failure of system components. Timely removal of these noble metals and gases would ensure the safe operation of the reactor system. The dynamic nature of salt fuel system, involving the generation, decay, deposition, and extraction of noble metals and gases, calls for robust species transport models to facilitate system analysis and monitoring, and design of efficient species removal components. This paper concentrates on the development of a computational framework for species transport, consisting of multiphase transport model formulation, mass transfer between phases, numerical implementation in MOOSE environment, verification through Method of Manufacture Solutions (MMS) and validation against experimental data from the Molten Salt Reactor Experiment (MSRE). Integrating this framework into the System Analysis Module (SAM) code further enhances SAM’s capabilities for advanced reactor analysis in the future.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2024

Liquid metal walls

Here, the plasma performance of fusion devices depends strongly on the chosen wall materials. Solid plasma-facing components (PFCs) are predominantly used in present devices, and are the most investigated candidates for fusion designs. High-Z materials such as tungsten (W) are the leading solid PFC material candidates. To date, a material choice that scales to steady-state reactor conditions has not been identified. Moreover, if plasma transient events such as edge-localized modes and disruptions cannot be altogether avoided or sufficiently mitigated, the projected peak heat and particle loads far exceed the power exhaust capabilities of solids. Liquid metal (LM) PFCs represent an intrinsic self-healing boundary that are both resilient to surface damage from transients, and that could handle high steady-state heat and particle fluxes. Flowing LM PFCs can be designed to remove “slag,” the buildup of material erosion due to plasma-material interactions, including charge exchange sputtering in the main chamber. Further, LM offer the prospect to manage hydrogenic species otherwise retained in the PFCs, which is important from a safety and inventory standpoint. The two most promising LMs are lithium (Li) and tin (Sn), although Sn–Li eutectics may be considered. While Sn offers a higher temperature window with low vapor pressure and low hydrogen retention, Li offers the prospect of enhanced energy confinement and higher acceptable core contamination limits, and this section focuses on Li PFCs. An LM PFC development research program developed LM PFC concepts for a nuclear fusion device via engineering design calculations, single-effect experiments, and staged prototypical experiments. A self-consistent design window was identified with liquid Li flow speeds ~5–10 m/s; plasma contamination was negligible for predicted Li evolution rates. While these preconceptual designs hold promise, there is substantial R&D needed to advance the technical readiness levels of LM PFCs for application to fusion power plants.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
NASA NTRS1969

Induction probe determines levels of liquid metals

Mutual-inductance probe accurately measures liquid levels in a variety of liquid metals at elevated temperatures. It can be used in pyrochemical processes for the recovery of spent reactor fuel.

Johnson, T. R.↗
NASA NTRS2010

Compact, Lightweight Electromagnetic Pump for Liquid Metal

A proposed direct-current electromagnetic pump for circulating a molten alkali metal alloy would be smaller and lighter and would demand less input power, relative to currently available pumps of this type. (Molten alkali metals are used as heat-transfer fluids in high-temperature stages of some nuclear reactors.) The principle of operation of this or any such pump involves exploitation of the electrical conductivity of the molten metal: An electric current is made to pass through the liquid metal along an axis perpendicular to the longitudinal axis of the flow channel, and a magnetic field perpendicular to both the longitudinal axis and the electric current is superimposed on the flowchannel region containing the electric current. The interaction between the electric current and the magnetic field produces the pumping force along the longitudinal axis. The advantages of the proposed pump over other such pumps would accrue from design features that address overlapping thermal and magnetic issues.

Godfroy, Thomas↗