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DOE OSTI2025

Computational materials reliability assessment of hydrogen fueled gas turbine power generation engines

The use of blended fuel sources in land based gas turbine engines drives variations in the resulting operational profile (temperatures and pressures) which can impact engine reliability. Furthermore, variability in the manufacture of components affects the resulting microstructure which directly impacts material performance and reliability. Currently, data-driven models are typically used for maintaining and inspecting fleets of engines. Without explicitly capturing material and operational sources of variability conservatism must be used in developing component-level reliability models. Therefore, there exists an opportunity to use information from materials-scale physics models to better inform reliability modeling and reduce conservatism; the impact is more cost-efficient operation and maintenance of current and future fleets. Specifically, this work establishes a computational framework for evaluating the probabilistic high temperature creep performance of hot-section Ni-based superalloys where uncertainty comes from both microstructural and operational variability. A novel high-fidelity physics model which phenomenologically captures grain-boundary sensitive phenomena has been established. A probabilistic calibration procedure was used to calibrate the model and capture uncertainty in the parameterized model coefficients. A design of experiments methodology was established for identifying informative microstructural digital representations for suitable for forward model evaluation. Results show that training a machine-learning surrogate using this design criteria outperforms random selection of microstructural representations. Finally, two surrogate models were developed: (1) a deterministic surrogate model which predicts the local field response given microstructure, constitutive model parameters, and operating conditions (stress, temperature) and (2) a probabilistic model, where uncertainty comes from constitutive law uncertainty, built using denoising diffusion probabilistic models which samples responses given (1) microstructure and (2) operating conditions. These surrogate models enable partner Siemens Energy to rapidly perform UQ analysis specific to creep deformation across a range of microstructures and operating conditions. The impact is that these ML and physics codes can be used to establish more advanced reliability models for the inspection, servicing, and maintenance of land based gas turbine engines.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Gimballed Tracking Mount Pointing Angle Qualification

Tonopah Test Range (TTR), in support of its testing mission and modernization effort acquired a fleet of new gimballed tracking mounts (GTMs) manufactured by BAE Systems. The new GTMs can be operated remotely during flight tests and provide near real-time target tracking data. Furthermore, test vehicle Time-Space-Position-Information (TSPI) is evaluated using post-test synchronized imagery and pointing angle measurements acquired from each tracking mount. To comply with the Nuclear Enterprise Assurance Program (NEAP), all measurements devices must be certified. In keeping with the NEAP program, qualification of the new GTMs have been assessed to confirm that their pointing angle measurements produce acceptable TSPI results. This study only evaluated the four GTMs as a stand-alone solution and found that the GTMs meet their performance requirement of 0.006 degrees RMS error (or less) for post-processed pointing angles and produced TSPI solution with error volumes on the order of one meter or less. The new GTMs will be utilized in combination with existing optical tracking mounts, which will only improve the accuracy of the resulting TSPI data product. Details regarding the approach, analysis, summary results, and conclusions are presented.

42 ENGINEERING↗

DOE OSTI2026

Analysis of Truck Platooning on Rural Highways

An analysis by the National Laboratory of the Rockies on truck platooning technology used on Ohio highways found that truck platooning operated for 40% of driving distances, showcasing its potential to enhance freight efficiency and safety. While energy savings were evident, further optimization of gap distances and operational consistency is needed to fully evaluate fuel savings benefits across diverse driving conditions. While more study is needed, advanced connected and automated vehicle technologies such as platooning demonstrate significant promise for transforming commercial vehicle efficiency and operations.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2020

Experimental and Kinetic Modeling Study of Laminar Burning Velocities of Cyclopentanone and Its Binary Mixtures with Ethanol and n-Propanol

Cyclopentanone is a promising biofuel that can enable more efficient engine operation and increase the fuel economy of the light duty fleet over current and planned technology developments. While the ignition of cyclopentanone has been investigated in detail, more studies on the laminar burning velocities of cyclopentanone are called for. In this work, the laminar burning velocities of cyclopentanone (C 5 H 8 O) have been measured using the heat flux and spherical flame methods at 1 atm, equivalence ratios from 0.7 to 1.6, and initial temperatures of 328, 353, and 428 K. To further investigate the relationship between the molecular structure and laminar burning velocity, identical experiments were also performed for binary mixtures of cyclopentanone with ethanol and n-propanol at 1:1 (mol). The consistency between the experimental data sets obtained in this work and literature data sets has been evaluated. Here, a recently published mechanism of cyclopentanone was used for simulation after adopting the submechanism of n-propanol. Good agreement has been seen between experimental and simulated results for all flames. To qualitatively explain the characteristics of the laminar burning velocity of cyclopentanone and the differences with those of ethanol and n-propanol, sensitivity analysis and reaction pathway analysis have been performed to compare the chemistry of the fuels under flame conditions, which revealed how the molecular structure of cyclopentanone could affect its laminar burning velocity. Compared to ethanol and n-propanol, cyclopentanone does not have primary carbon atoms in its molecule, leading to lower production of methyl radicals. Meanwhile, the carbonyl group in the cyclopentanone molecule is mostly released as CO in the decomposition of multiple intermediates accompanied by the production of unsaturated C 2 and C 4 species, especially C 2 H 4 and C 2 H 3 . Both features contribute to the high laminar burning velocity of cyclopentanone.

09 BIOMASS FUELS↗

DOE OSTI2023

Preliminary Nuclear Containment Vessel Modeling for Multi-Hazard Probabilistic Risk Assessment under Seismic Hazards and Concrete Degradation

The current practice for natural phenomena hazards (NPH) risk assessment of nuclear facilities is to compute the risk for each hazard independently and then compound the total risk as a combination of single hazard risks. This state of practice does not consider correlations between hazards and the cascading impacts to structures, systems, and components (SSCs), and could thus underestimate the NPH risk or overestimate the nuclear facility safety. Events such as the Fukushima Daiichi accident have highlighted the importance of multi-hazard risk considerations to nuclear power plants (NPPs) that quantify the cascading damage effects to SSCs in the risk models. Moreover, the current fleet of NPPs in the United States is aging; these NPPs are now expected to operate well beyond their initially planned design life. Aging-related deterioration can potentially decrease the capacity of critical structures such as containment vessels to withstand NPH. Such aging considerations may not be adequately accounted for by the current NPH risk assessment guidelines. This paper presents a preliminary modeling and simulation of a representative reinforced concrete containment vessel subjected to seismic mainshock and aftershock considering concrete degradation due to alkali silica reaction. The broader aim is to develop multi-hazard time-dependent fragility functions that could be subsequently used in the probabilistic risk assessment (PRA) model. The multi-hazard component comes into play due to the consideration of damage to the containment vessel under seismic loads and concrete degradation. Consideration of concrete degradation also brings into play the time-dependent nature of the containment vessel response. The response of the containment vessel under varying degrees of concrete degradation to seismic loads is investigated. The results presented are simulated using the Multi-hazard Analysis for STOchastic time-DOmaiN phenomena (MASTODON) software for seismic analysis and the Blackbear software for concrete degradation and damage modeling. Both software are open source and developed within the Multiphysics Object-Oriented Simulation Environment (MOOSE).

42 ENGINEERING↗

DOE OSTI2025

Quantitative Risk Assessment for Fuel Cell Electric Bus Hydrogen Storage and Refueling Facility

It is necessary to understand the safety implications and risk mitigation options for fuel cell electric bus fleet deployment, especially for related facilities responsible for operations such as production, storage, compression, and dispensing of hydrogen for use by the buses. In this report, we present a quantitative risk assessment for a potential fuel cell electric bus fleet that was motivated by efforts to improve resilience at the Portland International Airport but can be applicable to a range of hydrogen case studies and use cases. We estimated risk for a facility that produces, stores, compresses, and dispenses hydrogen for the fleet of buses, with a focus on individual risk to people in terms of annual frequency of fatality. We considered the frequency of hydrogen leaks that could result in harmful physical outcomes like jet fires or explosions, and the consequences of those outcomes for people. We created customized fault trees to calculate the frequencies of different sizes of leaks and event sequence diagrams to calculate ignition probabilities for the various leak sizes. We also leveraged the HyRAM+ toolkit to use these inputs to calculate overall risk for the facility, which we separated into one section responsible for producing, storing, and compressing hydrogen, and one section responsible for dispensing the hydrogen to the buses. We found that the dispensing area seemed to have a higher risk than the production/storage/compression area of the facility, largely because of the inclusion of a component with a high leak frequency (the heat exchanger used to cool the hydrogen before entering the vehicle, to prevent overheating and expansion of hydrogen in the onboard tank). For the example production and refueling facility we evaluated and the data we used for the analysis, the leak frequency had a larger impact on the risk differences between the two sections on the facility, compared to the physical outcome consequence, which was slightly different due to the varying fuel conditions, but not substantially different. Actions can be taken to prevent these hazards (e.g., lowering leak frequencies in system components) or to mitigate the consequences if they do occur (e.g., installing barriers to protect people if ignition events occur). The choice of which actions to take depends not only on safety considerations but also on space, time, staffing, feasibility, and financial constraints. Therefore, the quantitative risk assessment approach can help understand relative risk contributions from different components, leak sizes, consequences, and human actions, to prioritize risk reduction strategies and balance these parameters. The outcomes of this report may be useful for a variety of stakeholders working in the hydrogen, transportation, vehicle, and aviation sector, including those responsible for aspects like facility design, operations, and regulations. There is not a single value of risk that determines whether a hypothetical system is “safe” or not. The insights about risk mitigations may be leveraged, and the quantitative risk assessment approach can be applied to other case studies to understand risk priorities and contributions specific to different FCEB and hydrogen facility uses.

08 HYDROGEN↗

DOE OSTI2020

A Community Energy Operations and Planning System: Concept, Use cases, Metrics, and Benefits

Community and city leaders are interested in achieving sustainability goals, providing resilient energy infrastructure, and improving economic competitiveness. Community-level data acquisition and analysis can provide energy and associated benefits that are not possible at the single building level. However, there is a lack of organizational structure, common semantic data models, interoperable systems, and methods to support data-driven decision-making for community-scale energy supply and demand systems. We explored the need and opportunity for a Community Energy Operations and Planning System (Community EOPS), a potential data exchange platform. We conducted “customer discovery” interviews, and reviewed literature, public tools, and technology platforms to identify key energy data “users” and use cases in communities. The key users of the Community EOPS could be developers of mixed-use districts, corporate, defense and university campus energy managers, and city managers of cities that own their energy utility. The value could be for community planning and reporting (for energy data-integrated land use planning and community infrastructure investments in microgrids, storage, district heating and cooling), energy efficiency (leveraging optimizations for community scale energy supply and demand), flexible load management (grid-edge load management to offset, shift, and flatten loads for multiple buildings and EV fleets), cost savings and revenue generation (participating in grid services), and social benefits such as energy resilience, equity, and awareness. We developed a conceptual Community EOPS architecture with recommendations for streamlined and prioritized data acquisition, sharing, and integration driven by prioritized use cases, common metrics, and actionable visualizations that can provide value to a community’s users.

Singh, Reshma↗

DOE OSTI2026

Feasibility and strategic implications of deploying nuclear power reactors in Africa

This report assesses the feasibility and strategic implications of deploying nuclear power reactors, including large-scale plants, advanced small modular reactors (SMRs), and microreactors, in African countries. Case studies focus on South Africa, Egypt, Kenya, Ghana, and Nigeria, examining nuclear energy’s role in Africa’s rapidly evolving energy landscape, marked by fast-growing demand, significant electricity access gaps, increasing renewable penetration, and strong policy commitments to industrialization and energy security. Several U.S. reactor technologies and designs are considered based on their development status and readiness for deployment. The analysis finds that nuclear power can provide reliable, clean baseload and flexible generation, as well as high-temperature process heat for desalination, hydrogen production, and industrial applications. However, suitability is highly country-specific, depending on grid size and stability, transmission capacity, cooling water availability, regulatory readiness, and fuel supply chains. Near-term deployment opportunities are strongest for light-water reactors (such as NuScale, BWRX-300, AP300, and SMR-300) that use low-enriched uranium and build on proven technology. More advanced concepts, including gas-cooled, sodium-cooled, molten-salt cooled reactors, and microreactors, will likely be relevant for African deployment in the 2030s or later, contingent on demonstration projects, high-assay low-enriched uranium (HALEU) fuel availability, and mature international licensing frameworks. Economic analysis shows that SMRs are capital-intensive, with projected overnight costs for 300 MWe units in 2025 ranging from approximately 1.4 to 2.6 billion USD per module. The levelized cost of electricity (LCOE) is highly sensitive to the weighted average cost of capital (WACC). Given typically higher financing costs and utility balance-sheet weaknesses in many African countries, bankable project structures will require sovereign guarantees, robust offtake arrangements, and layered financing from export credit agencies, development finance institutions, and vendor nations. Comparisons with recent large nuclear projects in the United Arab Emirates (UAE) and Egypt underscore the central role of state-backed loans, long tenors, and concessional terms. Country case studies illustrate a spectrum of readiness and opportunity. South Africa operates two 920 MWe pressurized light water reactors (totaling 1,840 MWe) at Koeberg and has the most mature regulatory and industrial base, positioning it as a prime candidate for both large reactors and SMRs to replace coal, support desalination, and anchor industrial hubs. Egypt is constructing four VVER-1200 units at El Dabaa with strong state leadership and could later complement this fleet with SMRs for coastal and industrial applications. Kenya and Ghana are advancing through IAEA Milestones with growing institutional capacity and clear interest in SMRs that match their smaller grids and industrialization plans. Nigeria has the largest demand potential but faces acute constraints in grid reliability, project bankability, and regulatory capacity; targeted deployments of large reactors and SMRs near coastal or industrial sites could have high impact if accompanied by major grid upgrades and institutional reforms. The report identifies cross-cutting challenges such as financing, political continuity, public acceptance, nonproliferation and security, waste and back-end management, regulatory capacity, grid adequacy, and long deployment timelines for first-of-a-kind designs, and ANL/NSE-26/3 ii proposes broad directions for resolution. These include stronger multifaceted financing for nuclear, long-term national energy strategies that transcend electoral cycles, proactive stakeholder engagement, strengthened regional and national regulators, and systematic workforce development through centers of excellence and expanded training. The United States should develop partnerships with African countries and offer end-to-end nuclear package similar to those used effectively by competitors: coordinated project development, state-backed financing, long-term fuel services, and durable in-country support through regional offices and sustained workforce/regulatory training. With timely planning, sustained political commitment, and appropriate financing and institutional support, nuclear energy, both large reactors and advanced SMRs, can become a meaningful, though not dominant, pillar of Africa’s future power mix, enhancing energy security, enabling industrial growth, and supporting climate goals.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

Development of wind turbine blade recycling baselines in the United States

Over the past several years, the wind energy industry has received scrutiny regarding wind turbine blade (WTB) recycling due to the landfilling of WTBs caused by a lack of industrially viable recycling solutions. The amount of WTBs that will need to be recycled is set to increase in the United States as the deployment of wind energy is expected to rapidly grow to meet the nation's energy goals by 2035. While significant progress has been made worldwide, it is still unclear which WTB recycling solutions would be the most cost and energy effective within the United States for the existing fleet of wind turbines. To guide researchers and industry with a clear path forward, a range of options for WTB recycling in the United States are modeled through development of baseline scenarios and the use of formal life cycle assessment (LCA). Model data have been collected through literature review, industry engagement, and expert opinion regarding current end of life practices and considerations surrounding equipment, labor, and logistics. A detailed baseline for WTB decommissioning processes has been developed and used to assess alternative approaches, such as on-site shredding to compare the impacts on greenhouse gas (GHG) emissions. The developed LCA model and baseline scenarios for WTB recycling is used to assess the current WTB decommissioning practices in the United States along with emerging recycling pathways, including cement kiln co-processing and pyrolysis. Initial findings indicate that there are different approaches to decommissioning WTBs in the United States, each of which has unique implications for recycling. In light of this finding, additional results from the modeling will be used to better understand decommissioning practices and assist in making educated decisions on recycling pathways for the future. Throughout the analysis, focus was given to where international efforts might differ from the United States. WTB recycling is occurring worldwide, and different countries have different drivers for creating markets for recycled WTB materials. The contrasts and similarities between the United States and other countries offer insight to areas of opportunity that the United States could investigate and areas that can be readily transferred from existing solutions. By modeling and characterizing the current decommissioning practices and potential recycling solutions for the United States, a clearer vision will be created for pathways forward as to how to handle end of life WTBs to enable more efficient and cost-effective opportunities for material recovery from end-of-life WTBs.

Korey, Matt↗

DOE OSTI2022

The international research reactor conversion effort and its contribution to the validation of reactor physics and thermal-hydraulics codes

Full text of publication follows. With about 200 reactors in operation, civilian Research and Test Reactors (RTRs) represent approximately a third of the global nuclear fleet. RTRs make use of core designs that are drastically different from commercial power plants to perform a wide variety of non-power applications that greatly benefit society. Because they often rely on high neutron fluxes, RTRs are designed with relatively compact cores and as a result, prior to the 1980's, were often deployed using Highly Enriched Uranium fuel (HEU, {sup 235}U/U = 20 wt. %). Due to proliferation concerns, the international community aims at eliminating the use of HEU in civilian facilities and favor instead the use of Low Enriched Uranium fuel (LEU, {sup 235}U/U < 20 wt. %). A program to support conversion of the world's RTRs to LEU fuel has been initiated in 1978 by the U.S. Department of Energy (DOE). This program is still alive today and has achieved more than 103 conversion metrics. Today, the program focuses heavily on the conversion of so-called high-performance RTRs, which are far more challenging than previous conversions as they require new fuel element designs and the use of new, higher density LEU fuel forms. Development and qualification of new LEU fuel elements is ongoing and requires extensive engineering analysis and testing. Both activities require the development and validation of codes and methods for reactor physics, thermal-hydraulics, and multi-physics, which in turn rely on experiments performed in RTRs or other experimental facilities. This talk will present the collection of RTR experimental data and benchmark analyses from the international conversion program that contribute to the validation of computer codes and methods.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2021

Future Battery Material Demand Analysis Based on U.S. Department of Energy R&D Targets

The U.S. Department of Energy’s Vehicle Technologies Office (VTO) supports research, development, and deployment of efficient, sustainable transportation technologies that will improve energy efficiency and fuel economy, and enable America to use less petroleum. To accelerate the development and adoption of new technologies, VTO has developed specific targets for a wide range of powertrain components, including the energy storage system. In this study, we use Autonomie, Argonne National Laboratory’s (Argonne’s) vehicle system simulation tool to evaluate future energy storage requirements (power, energy, etc.) for different vehicle classes, powertrains, component technologies and timeframes. BatPac, Argonne’s tool dedicated to energy storage pack design and costs, is then used to quantify the materials required for each pack. Market penetrations are then used to estimate the overall material demand worldwide and in the United States, with or without recycling. The results demonstrate that the positive impact of VTO research and development will lead to significant reduction in material compared to business-as-usual due to new anode and cathode designs, along with acceleration in battery cell chemistry penetrations. In terms of material demands, it is observed that lithium demand reaches about 80,000 tons (by a factor of 42–45), nickel demand reaches about 500,000 tons (by a factor of 47–56), manganese demand reaches about 30,000–50,000 tons (by a factor of 20–34), and cobalt demand reaches about 30,000 tons (by a factor of 13–28) in the future by 2050. The individual material demand per unit energy, however, decreases significantly in the future due to advances in VTO research and development activities. The increase in battery material demands is mostly driven by increased electrified vehicle fleet penetration in the markets.

25 ENERGY STORAGE↗

DOE OSTI2022

Demonstration and Evaluation of the Human-Technology Integration Function Allocation Methodology

There is an imminent need for the existing nuclear power plants to reduce their operating and maintenance (O&M) costs to remain economically viable. Digital technology, including automation, provides a significant opportunity for the existing nuclear power plant fleet to transform the way in which work is accomplished, reducing O&M costs, and allowing the fleet to remain economically competitive. One notable opportunity to significantly reduce O&M costs pertains to modifications to the plant equipment and main control room (MCR). Existing instrumentation and control (I&C) technologies in the MCR are highly analog, costly to operate and maintain, and demand a high cognitive and physical workload from plant staff (i.e., operators). Digitalizing the MCR has a range of broad economic benefits, including improved plant performance and reduced manual work. Further, digital I&C systems can fundamentally change the way in which plant staff operate the plant; this is the concept of operation. Human-technology integration is important to ensure that impacts to the concept of operation are done in a way that account for capabilities of people and technology. Human-technology integration employs human factors engineering (HFE) methods and principles to maximize the benefits of digital technology, reducing human error, improving overall decision-making and usability. The U.S. Department of Energy Light Water Reactor Sustainability Program is applying human-technology integration research to ensure digital technologies are safe, reliable, and efficient. This paper documents the demonstration of the human-technology guidance developed by the Light Water Reactor Sustainability Program from a first-of-a-kind digital I&C upgrade, specifically addressing function analysis and allocation for a new digital I&C system that included changes in automation levels. The program’s specific approach is included in this work, following lessons learned. This document serves as a resource for industry to follow in applying human-technology integration and HFE to digital modifications, specific to function analysis and allocation. The lessons learned should be considered in the planning and execution of HFE activities that support such digital modifications.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI2026

FleetREDI Insight: Beverage Delivery in New York City

Capturing real-world data is critical to improving efficiency and supporting technology advancements in commercial vehicles. FleetREDI’s insights provide detailed duty cycle information and highlight unique aspects of the given dataset. Each insight delivers a quick look at the collected data by summarizing the operation and identifying key findings of the initial analysis. This FleetREDI insight explores beverage delivery tractors operating in New York City. Last-mile beverage delivery supports local bars and restaurants throughout Manhattan and the broader New York City area. Manhattan Beer Distributors is a beverage delivery company operating in Manhattan and the Bronx. Logging devices were installed in 17 vehicles, and operational data were collected between August and October 2022. Two types of vehicles were included in data collection: 7 tractors and 10 bay trucks. Using NLR’s FleetREDI data platform, this dataset provides a summary of daily operation to help understand duty cycle characteristics. This includes daily distance, fuel use, and estimated engine-produced energy consumption for 17 bay trucks and tractors that operated more than 7,500 miles in slow-speed urban operation. ![FleetREDI beverage delivery](FleetREDI-beverage-delivery-nyc.jpg)

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Report on the Creation and Progress of the Hydrogen Regulatory Research Review Group

The current U.S. nuclear generation fleet is increasingly recognized by governmental, scientific, public policy, and industrial communities as having a strategic role in support of the ongoing national transition to a clean energy future. Federal incentives and actions are aligning to expand the role of nuclear power as a viable and more flexible contributor to the evolving national clean energy mix through programs and initiatives such as nuclear power loan guarantees; the Inflation Reduction Act’s (IRA) clean nuclear electrical, steam, and hydrogen incentives; the Infrastructure Investment and Jobs Act (IIJA, also referred to as the Bipartisan Infrastructure Act or BIL); and near term Department of Energy (DOE) funding opportunities related to nuclear based hydrogen hubs and nuclear integrated hydrogen demonstration projects. . Additionally, leveraging clean nuclear electricity and steam is being explored by industries desiring to transition away from carbon-intensive energy sources. Even with all these emerging enablers, notable barriers remain for the widespread adoption of these opportunities within the U.S. nuclear fleet, including the following: • Assurance of the markets for alternate products needed to support decision-making for large capital modification investments • Electric utility mindset and business history centered solely on producing electricity • Design change complexity and regulatory uncertainty associated with plant modifications needed to support alternate product streams The DOE Light Water Reactor Sustainability (LWRS) Flexible Plant Operations and Generation (FPOG) Pathway is developing options to help U.S. nuclear power plants (NPP) in all these areas to enable NPPs designed for steady baseload operation to integrate with intermittent wind and solar capacity to assure reliable clean energy for the nation. Current and near-term laboratory research is focusing on the technical, regulatory, safety, demonstration, and economic elements in support of improving nuclear plant flexibility through hybrid production of electricity and other non-electric products such as hydrogen and energy arbitrage.

42 ENGINEERING↗

DOE OSTI2020

An Update on Cardinal: Toward Full Core Pebble Simulations

The new DOE-NE Center of Excellence for Thermal-fluids applications in Nuclear Energy inaugurated in April 2018 considers and researches novel new solution strategies for historically challenging flow issues that still plague the current fleet of deployed Light Water nuclear Reactors (LWRs) as well as predicting various fluid flow and fluid related issues with advanced reactor technologies. Our advanced thermal-fluids research and development approach synergistically combines three natural, though overlapping, length and time scales in a hierarchal multi-scale approach to avoid the temptation and pitfalls of attempting to develop a single solve-all algorithm for physical fluid flow problems that will span nine orders of magnitude in spatial and temporal scales. To demonstrate the multi-scale philosophy of the center we focus on Fluoride Cooled High Temperature Reactors (FHRs), and in particular on the Berkley’s PB-FHR Mark-I design. The Fluoride salt cooled High temperature Reactor (FHR) is a class of advanced nuclear reactors that combine the robust coated particle fuel form from high temperature gas cooled reactors, direct reactor auxiliary cooling system (DRACS) passive decay removal of liquid metal fast reactors, and the transparent, high volumetric heat capacitance liquid Fluoride salt working fluids - such as Flibe - from molten salt reactors. This combination of fuel and coolant enables FHRs to operate in a high-temperature low-pressure design space that has beneficial safety and economic implications. The PB-FHR reactor relies on a pebble bed approach and pebble bed reactors are in a sense the poster child for multi-scale analysis. The lower length-scale simulator for pebble reactor cores comprises three physics: neutronics (OpenMC), thermal-fluids (Nek5000/NekRS) and fuel performance (BISON). As part of Center of Excellence ongoing research efforts we have developed Cardinal, a new tool platform for lower length-scale simulation. Cardinal tightly couples all three physics and leverages advances in MOOSE such as the MultiApp system and the concept of MOOSE-wrapped Apps. The present report provides an update on the development of Cardinal with an extension of Cardinal to GPUs. We also perform a first-of-a-kind demonstration simulation on Summit representing a 10x capability increase in terms of pebble count for Cardinal.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2024

Hydrogen Generation and Industrial Heat Opportunities for Nuclear Plants in the Gulf Coast

The United States (U.S.) nuclear-generation fleet stands as a critical national strategic asset, playing a pivotal role in achieving climate goals. Operating on light-water reactor (LWR) technologies, this fleet provides the largest share of U.S. carbon-free electrical generation, ensuring 24/7 clean-energy stability. With a proven track record of reliability while operating at high-capacity factors, consistently above 90%, the existing nuclear fleet serves as a cornerstone for sustainable energy. The Department of Energy’s (DOE’s) Light Water Reactor Sustainability (LWRS), Flexible Plant Operations and Generation pathway addresses U.S. nuclear power plant (NPP) grid integration challenges in the face of evolving energy landscapes. Research at Idaho National Laboratory (INL) highlights the potential synergy between high-temperature steam-electrolysis (HTSE) technology and nuclear steam and electricity during periods of high renewable grid penetration. Large-scale nuclear-integrated hydrogen production through HTSE presents significant potential for decarbonizing such energy-intensive sectors as oil refining, petrochemicals, ammonia, and fertilizers. The strategic advantage lies in the nuclear sector’s capability to deliver clean electrical and/or steam output during periods of low demand. Nuclear-produced hydrogen—with its ability to provide high-purity clean H 2 well below the national standard of 1 kg of CO 2 per kg of H 2 —represents a breakthrough methodology. This emphasizes the crucial role NPPs can fill in addressing the increasing need for clean hydrogen, establishing them as essential contributors to decarbonization. This report specifically delves into hydrogen-generation opportunities from the U.S. Gulf Coast region. This study aims to assess NPP capabilities for hydrogen production and to identify practical nearby industrial and pipeline-operator off-takers for nuclear-integrated hydrogen production as well as to present some specific case-study analysis showing the conditions under which nuclear hydrogen production and sale can be profitable. Also considered in this report is preliminary analysis of nuclear-heat opportunities accessible near Waterford NPP via transportation of hypothetical steam pipelines and heat-exchange equipment.

08 HYDROGEN↗

DOE OSTI2021

Medium and Heavy Duty Vehicle Powertrain Electrification and Fleet Demonstration

The Contract Award Grant # EE0007513 dated 2 June, 2016 is for the design, development and demonstration of medium duty package delivery vehicles that will result in a 100% increase in fuel economy as measured in miles per gallon. The project was proposed in 3 phases over two budget periods. The Phases were: 1. Modeling and Simulation – This phase was completed and formed the basis of the specifications for the design and build of the physical systems. The modeling and simulation was conducted by AVL and used real world package delivery routes that AVL mapped. The motors, battery pack, range extender and balance of plant support systems were modeled and iterated until a system with the desired fuel economy improvement was realized. Early design of the major subsystems using the actual vehicle space constraints was also completed. This phase was successfully completed in May of 2017. 2. 1st Build and FE Confirmation - This phase was completed and resulted in the final design, release, procurement and build of all major vehicle systems for commissioning into the first vehicle. The work was a partnered effort between McLaren and AVL. McLaren built the eAxle system while AVL built the range extender and integrated the range extender, battery and balance of plant sub-systems into the first vehicle with a control system to make it operate. Prior to the end of this phase a real world HIL system test gave evidence that the fuel economy improvement would be achieved in the real world. This phase was exited with a 7 month delay due mostly to procurement and supply base issues and ended in May, 2018. 3. Final Build and Demonstration - This phase included the final build and commissioning of the four program vehicles and the operation of a demonstration on a set of routes near San Diego California. During this phase, a multitude of issues arose in different systems in the vehicle. These issue resolution exercises were quite complex and caused repeated delays but were all successfully completed. It should also be noted that an early commercialization analysis resulted in the conclusion that the complexity of the system would not make it cost effective, leading to the start of a follow-on design that used newly available component technologies to specify a more cost effective system. This design will be repurposed and put into demonstration on a separately (non-DOE) funded program. It was decided and agreed with DOE that this phase should be considered completed. The knowledge and know-how gained on this program has been incorporated into and transferred to the new program. This phase and the entire program was considered closed on June 1, 2021.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2020

Montana Community-Scale Solar Strategy Project (Final Technical Report)

Grid-tied solar photovoltaic (PV) development began gradually in Montana, initially taking root in the early 2000s, largely in the form of small residential systems, rarely larger than two kilowatts. Utility support for solar technology through public benefit funding triggered the installation of the state’s first solar PV installations on community-owned facilities including schools, libraries, fire stations and local government buildings in the mid-2000s. By 2016, solar PV installations totaled approximately 28 megawatts of installed capacity, generating less than 0.05% of electricity sold in Montana. Montana’s solar fleet in 2016 included 17 megawatts of utility-scale solar farms, and three shared solar projects developed by rural electric cooperatives that ranged from 25 to 50 kilowatts in size. However, with only 3,000 households utilizing solar PV, either through an on-site installation or participation in a shared solar project, the potential benefits and reach of solar technology was limited. The Montana Solar Community Project (MSCP) was developed by the Montana Energy Office (MEO) at the Department of Environmental Quality in order to implement a “community-scale” solar energy strategy for the state that would cost-effectively expand Montanans’ access to solar PV. This project defines three types of community-scale solar projects: shared solar, community-sited solar, and group purchasing programs. The MSCP project conducted research and stakeholder engagement that helped to inform and develop model community-scale initiatives and an overarching community-scale solar strategy for Montana. Specifically, the project included a solar market assessment, stakeholder meetings across Montana, development of a menu of community-scale solar options, a study of solar potential on schools, community solar market research, and community-scale project implementation support. MSCP activities were successful in implementing solar projects and supporting solar development in communities across Montana. Project activities realized 280 kW of newly installed solar from two solarize programs, a shared solar array at a rural electric cooperative, and a solar array atop a Bozeman high school. The community-scale project implementation support and Solar on Schools components of the project resulted directly in the analysis and design of nearly 2 MW of distributed solar systems across the state. The Solar on Schools analysis alone produced solar designs for 25 schools, representing 920.8 kW of solar potential. Many of the deliverables from this project provide guidance on future development of community-scale solar in Montana, and resulted in a number of important conclusions about community-scale solar in Montana. There is strong interest in community-scale solar in Montana, as noted during stakeholder meetings, in response to solar market research surveys, and as seen by applications for implementation support grants provided by MEO. Project activities also suggest that Montanans demonstrated a desire and need for more information about solar energy technology, solar financing options, and the state’s policy and regulatory framework. Additionally, the project found that schools will be key partners for future community-scale solar programs. In addition to being excellent hosts for solar arrays, schools have the opportunity to use the installation of a solar array to develop educational materials and curricula to educate Montana’s future leaders about these technologies, which can be shared and replicated across the state. Project activities laid a clear path forward for solar energy in Montana. Certain activities have concrete next steps. For example, numerous solar arrays were designed for schools and other public buildings around the state. Many of those designs will be used as soon as funding becomes available. Other activities have less developed next steps, though lay the foundation for future work. The solar market assessment, solar market research, and community stakeholder meetings are good examples. These documents can be used as stepping stones to increase renewable energy education, increase stakeholder outreach, and support communities as they seek to develop community-scale solar projects.

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