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DOE OSTI2023

Cost details from front-end engineering design of piperazine with the advanced stripper

This Front-End Engineering Design (FEED) was funded by the U.S. Department of Energy (DOE) to estimate the cost to capture and compress 90% of the CO 2 from an existing natural gas combined cycle (NGCC) in Denver City, Texas, USA. The FEED used the PZAS (Piperazine with the Advanced Stripper) 2G amine scrubbing technology developed and modeled by The University of Texas at Austin. This FEED is unique in providing more public cost details than other FEEDs funded by DOE. The primary objective of the FEED was to provide a comprehensive estimate for the total installed cost of the capture plant. The estimated capital cost of NGCC at the Mustang Station is $\$727$ million for a capacity of 460 MW and 1.6 million tonnes CO 2 /yr. This includes a contingency of $\$104.6$ million and a contractor’s profit of $\$60.1$ million. The total direct field cost is $\$384.1$ million. With an optimistic fuel value of $\$3$/MMBtu, the estimated cost of capture varies from $\$85$/t at 4% IRR/85% load to $\$170$/t at 10% IRR/52% load. Air cooling is technically feasible but expensive. The air cooling systems for the water wash and pump-around intercooling account for 23.4% of the direct cost. The gas-fired boilers represent only 4% of the direct costs, but steam extraction would reduce energy cost, free up cooling water, and reduce the direct costs of processing additional flue gas and CO 2 from the boilers. The absorbers represent 9.6% of the direct cost in this FEED with no direct contact cooler and only 7.6 m of packing. Furthermore, the solvent cross exchangers are less expensive than expected (2.5% of direct costs). Doubling the number of these exchangers could reduce the heat duty from 3.0 to 2.5 GJ/t CO 2 .

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2021

Report on Year-3 of Water NSTF Matrix Testing: Two-Phase Parametric Test Series

The Natural convection Shutdown heat removal Test Facility (NSTF) is large scale test facility constructed at Argonne National Laboratory to generate NQA-1 qualified validation data for passive decay heat removal systems in advanced reactor concepts. With support from the Department of Energy (DOE) offices of Advanced Reactor Technologies (ART) and Advanced Reactors Regulatory Development (RD), this facility reflects key features of a ½ scale, water-based, Reactor Cavity Cooling System (RCCS) and is intended to study the behavior, bound performance, and ultimately guide design decisions for passive decay heat removal systems. Since the facility also retains all aspects common to a fundamental boiling water thermosiphon, the generated experimental data sets are well poised to advance the understanding of fundamental natural circulation boiling and two-phase flow phenomena.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2023

PIPII cryoplant non thermal cycling updates

The Proton Improvement Plan-II (PIP-II) is a crucial upgrade to the Fermilab accelerator complex, featuring a new 800-MeV Superconducting Radio-Frequency (SRF) linear accelerator (LINAC) with 23 cryomodules operating at 2K. The LINAC thermohydraulic conditions are satisfied by the cryogenic subsystems: Cryogenic Distribution System (CDS), a helium refrigerator cold box (CB), a warm compression station (WCS) and a helium recovery system (RSYS). The accelerator has a strict requirement of non-thermal cycling of the LINAC cryomodules during planned and unplanned subsystem outages. This paper presents an integrated operating modes analysis of the of the LINAC/CDS thermohydraulic loads satisfied by the CB/WCS cooling system supported by the RSYS inventory management system. The study is based on latest cryoplant and CDS engineering deliverables, as well as the recent performance data from single cryomodule qualification tests performed at the Fermilab PIP-II Injector Test test s tand. The study evaluates both normal and abnormal operating modes, with a focus on identifying integrated scenarios that put subsystems components under stress. The conclusions of this study will help build redundancy to reduce the risk of thermal cycles during planned and unplanned subsystem outages.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

DOE OSTI2022

Demand Driven Energy Management for PIPO Auxiliary Power Supply Architecture

In this paper, a demand driven energy management (DDEM) technique is implemented on modular parallel input parallel output DC/DC auxiliary power supply (APS) structure. In this method, modules are brought in/out of the operation making them operate under high loading conditions, avoiding low efficiency under light load. Such a method finds its application in power conservative systems with variable load. Implementation of DDEM and the energy saved is shown using APS comprised of two 15W commercially off-the-shelf DC-DC modules, with 100–1000 VDC input and 24 V output voltage. Along with the DDEM, the lifetime of the power stage devices is controlled minimizing their junction temperature swing through control of cooling system. This control method uses digital twin as interface to virtualize the power devices loading operation/ health condition. Accordingly, no extra sensor or closed loop control required to measure the junction temperature of the devices or feedback the losses to the cooling flow.

Azadeh, Yalda↗

DOE OSTI2023

Autonomous Intelligence Measurements and Sensor Systems (AIMS): Gaussian Processes in Remote Sensing: Literature Review

Power grid resilience and reliability is crucial to supporting critical infrastructure. Service interruptions can have devastating consequences to communication, emergency, and transportation services, just to name a few. In addition to infrastructure, power services are crucial to everyday life. Nearly every element of modern-day living relies on a stable and functioning power grid - heating and cooling systems to lighting, refrigeration, telecommunications, and internet access. Interruptions in the power supply can range from minor inconveniences, such as the temporary loss of internet or television services, to more significant problems, like the inability to access medical equipment or emergency services during critical situations. As climate conditions worsen, the reliability of the power grid becomes even more significant. Extreme weather events, such as hurricanes, wildfires, or severe storms, can cause serious damage to power infrastructure, leading to prolonged power outages. Rising temperatures and changing weather patterns can strain the grid, resulting in increased demand for electricity, stressing transmission and distribution systems.

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2023

State-of-the-art and review of condensation heat transfer for small modular reactor passive safety: Computational studies

The small modular reactor (SMR) is a promising option with added safety features, economical manufacturing, reliable parts, portability, and scalable energy capacity that emits no greenhouse gas during its operating lifespan. The SMR safety systems, however, need to be evaluated for design and licensing. Thus, they require the verification and validation of the physics models and correlations. This study focuses on state-of-the-art condensation heat transfer analysis and a review of previous studies related to the passive containment cooling system (PCCS) of a SMR. In the PCCS of a SMR, due to its smaller size containment, filmwise condensation is dominant and therefore emphasized in this study. Furthermore, previous condensation heat transfer studies for PCCSs did not make the SMR the primary focus, so a critical review for formulating the state-of-the-art is necessary. A previous review covered experimental condensation heat transfer studies with a brief overview of associated test facilities and empirical correlations. This review covers the empirical, resistance-layer and theoretical (numerical and commercial CFD) approaches.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2025

Simulations of the fault current limiting operation of a long-length REBCO CORC ® superconducting cable cooled by helium gas

Conductor-on-round-core (CORC®) cables composed of rare-earth-barium-copper-oxide high-temperature superconducting (HTS) tapes are of great interest for power transmission applications due to their many advantages such as high power density, light weight, and low loss. Closed circulation loops of cryogenic helium gas can be used to cool HTS cables down to low temperatures to significantly improve their current-carrying capacity. Coupled circuit-electromagnetic-thermal finite element simulations implemented in the COMSOL Multiphysics package were developed, validated, and then used for simulating the fault current limiting (FCL) performance and the cooling processes of an 8-layer CORC® cable cooled with a flow of cryogenic helium gas. In the simulations, the temperature dependence of the electrical and thermal properties of all component materials is implemented for improved accuracy. To overcome computational challenges caused by the considerable difference in geometrical scales (i.e. few-µm-thick HTS layers versus 10 m-long HTS cable), the model is divided into two separate simulations. The first simulation is performed on the transverse cross-section of the cable to calculate the electric field, heating power and temperature rise in each component of a CORC® cable during FCL operation. The heating power calculated in the first simulation is transferred to the second model to simulate the cooling of a 10 m-long cable after the fault is cleared. The effect of the helium gas flow rate on the cooling process is also investigated to develop strategic approaches for optimizing cooling systems for HTS cables with FCL capability. The simulations indicated that a 40 ms fault with a voltage drop of 20 V m −1 along the cable can result in a temperature increase from 60 K to about 165 K inside the cable, and it takes about 500 s to cool the cable back to nearly 60 K with a flow of cold helium gas at a rate of 5 g s −1 .

24 POWER TRANSMISSION AND DISTRIBUTION↗

DOE OSTI2024

Reduced Energy Demand for Cooling with the Sky

This project demonstrated the use of SkyCool’s Passive Daytime Radiative Cooling panels to improve the energy efficiency of cooling systems at Ft Moore, GA. These panels work by passively emitting heat to the sky during the day even under direct sunlight.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

FY23 Progress on Computational Modeling of the Water-Based NSTF

This report summarizes the system-level modeling effort by Argonne National Laboratory (Argonne) of the Natural convection Shutdown heat removal Test Facility (NSTF) in FY23. As a continuation of the modeling effort from FY22, this year’s work focuses on improving the RELAP5-3D model developed previously for two-phase flow simulations. The RELAP5-3D model is updated to more accurately capture the heat loss experienced by the facility. The updated model is compared against experimental data for benchmarking purposes of the RELAP5-3D input model. By correctly accounting for heat loss, the updated RELAP5-3D model can now predict the two-phase baseline case more accurately. The onset and the duration of instability are captured well by the model. Furthermore, analyses are performed to better understand the instability mechanism experienced by the flow where the expansion of the boiling boundary in the chimney is studied in details and the fundamental frequencies of the oscillations are obtained. The updated RELAP5-3D model is further compared against four fault conditions, namely the reduction of riser header inlet flow area, depletion of system inventory, blocked riser channels, and static boiling scenario. For each fault condition, minor modifications and tuning are performed to improve the predictions of the model. The purpose of the analyses is to investigate the capability of RELAP5-3D in predicting complex two-phase flows in possible accident scenarios in actual Reactor Cavity Cooling System (RCCS). Overall, the model is able to capture the behaviors and trends of these fault conditions relatively well. Some discrepancies remain between the experimental data and the predictions, many of which are likely due to the differences in the predicted and experimental vapor generation rate. Future work will focus on the continued development of the current RELAP5-3D input model of the NSTF to both improve the accuracy of the model’s predictive capability and continue supporting the experimental program needs. The mutually beneficial relationship between analysis and experimental efforts has become integral to the parent NSTF program, and the greater objective to fully understand and accurately predict the heat removal performance of a full scale RCCS concept.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2020

Experimental apparatus and methodology to test and quantify thermal performance of micro and macro-encapsulated phase change materials in building envelope applications

Thermal energy storage (TES) is used as a viable technology to shift peak electricity demand caused by the space cooling requirements in buildings. Passive TES is implemented in building envelope via micro and macroencapsulation methods. This study describes the use of a state-of-the-art laboratory to test different PCM inclusions in simplified building walls. A microencapsulated PCM and two macroencapsulated PCMs are tested in a controlled environment to gather data for validation purposes of PCM modelling algorithms in building energy modelling programs. Data indicates that the chamber environment and the heating and cooling system can conduct full-cycle tests of wall panels with PCM inclusions. This study also generates data from parallel tests on 4 wall panels which can be used in building energy modelling programs to validate the PCM modelling algorithms. The cyclic tests also capture the thermal effects of PCMs and complex PCM behaviors like sub-cooling in PCM hydrate-salts.

25 ENERGY STORAGE↗

DOE OSTI2022

Design and Verification of An Open-Circuit Electro-Hydraulic Actuator System with An Integrated Electro-Hydraulic Unit

This paper proposes an electro-hydraulic actuator (EHA) system, and two novel-designed electro-hydraulic units (EHU) consisting of a fixed-displacement hydraulic pump and a variable-speed electric motor. Both the novel EHU designs integrate an electric machine and a hydraulic machine in a single unit, featuring compactness and power density. However, they differ for salient aspects such as power and electric machine cooling system. The EHA system features an open circuit design, where hydraulic hoses connect the EHU with a tank, a valve manifold, and the hydraulic cylinder. In this way, the proposed EHA technology can be used to implement distributed hydraulic actuation in a vehicle without requiring changes to the hydraulic actuators or at the overall layout of the hydraulic components with respect to the original vehicle design. A dedicated test rig is developed to verify the performance of the proposed EHA system. The efficiency of the EHA is measured in a steady state and under a realistic duty cycle of a commercial compact loader. The measured efficiency of the system can reach 54% with up to 20kN load and 6kW power level.

42 ENGINEERING↗

DOE OSTI2024

Steam Condensation Scaled Experiment in the Presence of Non-condensable Gas for Reactor Containment Passive Safety Analysis

This study presents scaled experiments using steam condensation with non-condensable gas (NCG)—helium, simulating hydrogen—as these experiments are pivotal for water-cooled reactor passive containment cooling system (PCCS) design and analysis. Research into PCCSs for small modular reactors (SMRs) is especially important in light of SMR system design; however, studies in the literature reflect limitations due to test geometry and operational condition variations, without considering SMR prototypic design. To address these challenges, a scaled test facility was developed to accurately replicate SMR PCCSs. This facility includes vertical down-flow condensing test sections with 1-, 2-, and 4-in.-diameter condensing tubes, accompanied by annular water cooling. Experiments were conducted using both superheated and saturated steam, with steam mass flow rates varying from 55 to 66 kg/hr., in the presence of helium as the NCG mass flow rate ranges from 1.8 to 22 kg/hr. Test data were collected on (a) the axial temperatures of the annular cooling water; (b) the outer wall temperature of the condensers; and (c) the mass flow rate, temperature, and pressure at the test section inlets and outlets. These primary test data were used in conjunction with a standard data reduction methodology to estimate essential thermal parameters such as heat fluxes, heat transfer coefficients, and condensation rates. The effects of NCGs on steam condensation within the geometry of the scaled test sections were then presented in regard to various testing conditions.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2024

Presentation: Steam Condensation Scaled Experiment in the Presence of Non-condensable Gas for Reactor Containment Passive Safety Analysis

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2025

Facets of hydro power and future trends in a Nordic Context

Hydropower technologies bolster high penetration of variable renewable energies (VREs) in the net zero emissions scenarios. Nevertheless, there are various challenges to meeting the ambitious goal, such as stability, reliability, resiliency, security, lack of reactive power, voltage support and inertia, large-scale storage deployment and coordination, interconnectedness, demand-side response, higher thermal cycles with increased start/stops, and inadequate Levelized Cost of Energy (LCOE) for system-wise VRE integration and profitability. This survey conducts a bottom-up analysis to unveil the opportunities to utilize hydropower facilities and disentangle the nested problem for intertwining design features, control algorithms, operation, optimization approaches, incentives, services, and market mechanisms using a three-pillar framework perspective: grid owners, power producers, and machine designers. The survey identified emerging trends in real-time and capacity markets, flexible power systems, and enhanced grid capabilities, including advanced voltage support and updated grid codes. These developments present significant opportunities for hydropower, such as achieving super-flexibility through hybridization, expanded reactive power capabilities, and advanced operational modes like a synchronous condenser and power adequator functionalities. These opportunities require novel design philosophies — including new winding, stator, and rotor configurations, optimized ventilation, and active cooling systems — to enhance performance under stressed grid and climate conditions. Finally, integrating climate and energy models for multi-basin optimization with finer spatial and temporal granularity enhances the planning accuracy for water management of hydropower while addressing environmental challenges. The review delivers helpful prospective suggestions and tools that would serve researchers, power engineers, and stakeholders in making decisions about hydropower technologies and services in 2050 and beyond.

13 HYDRO ENERGY↗

DOE OSTI2024

Reactor Containment Passive Safety Analysis: Steam Condensation in Presence of Non-condensable Gas Scaled Experiment and Modeling

This study presents steam condensation scaled experiments and semi-empirical models in presence of nitrogen (N)—a noncondensable gas (NCG), simulating air in the reactor containment—to support water-cooled small modular reactors (SMRs) passive containment cooling system (PCCS) design and analysis. Previous experimental studies on PCCS are focused on fixed and smaller tube (mostly 2-in.) geometries and specific test condition variations, bringing challenges with geometric scaling and mismatching with SMR prototypic design. To address these challenges, this study presents steam condensation test dataset obtained from three scaled test sections of 1-, 2-, and 4-in.-diameter steam condensers with an annular/jacket cooling of 2-, 3-, and 6 in.-diameter tubes, respectively. Test data were collected for steam ranges from 58 to 63 kg/hr., and NCG flow of 4.4 to 13.3 kg/hr. Annular cooling water flow was varied to obtain required testing conditions of saturated steam inlet and fully condensed outlet. Axial temperature test data of bulk cooling water, steam and condensate were collected by thermocouples for three test sections and various steam-NCG mixing/testing conditions. A standard data reduction method was adopted—utilizing iterative and nodalized mass and heat transfer calculation—to estimate axial local heat fluxes, heat transfer coefficients (HTCs), condensation rates, film thickness, and Nusselt number. Based on the obtained dataset semi-empirical model results—a ratio of experimental and Nusselt’s theoretical HTC are presented. Such results and findings are supportive of developing scaled-up testing facility, to enable model validations and accelerate next generation of reactors development and deployment

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2024

Presentation: Reactor Containment Passive Safety Analysis: Steam Condensation in Presence of Non-condensable Gas Scaled Experiment and Modeling

This study presents steam condensation scaled experiments and semi-empirical models in presence of nitrogen--a noncondensable gas (NCG), simulating air in the reactor containment--to support water-cooled small modular reactors (SMRs) passive containment cooling system (PCCS) design and analysis. Previous experimental studies on PCCS are focused on fixed and smaller tube (mostly 2-in.) geometries and specific test condition variations, bringing challenges with geometric scaling and mismatching with SMR prototypic design. To address these challenges, this study presents steam condensation test dataset obtained from three scaled test sections of 1-, 2-, and 4-in.-diameter steam condensers with an annular/jacket cooling of 2-, 3-, and 6 in.-diameter tubes, respectively. Test data were collected for steam ranges from 58 to 63 kg/hr., and NCG flow of 4.4 to 13.3 kg/hr. Annular cooling water flow was varied to obtain required testing conditions of saturated steam inlet and fully condensed outlet. Axial temperature test data of bulk cooling water, steam and condensate were collected by thermocouples for three test sections and various steam-NCG mixing/testing conditions. A standard data reduction method was adopted--utilizing iterative and nodalized mass and heat transfer calculation to estimate axial local heat fluxes, heat transfer coefficients (HTCs), condensation rates, film thickness, and Nusselt number. Based on the obtained dataset semi-empirical model results--a ratio of experimental and Nusselt's theoretical HTC are presented. Such results and findings are supportive of developing scaled-up testing facility, to enable model validations and accelerate next generation of reactors development and deployment.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

DOE OSTI2024

Physics-informed State-space Neural Networks for transport phenomena

This work introduces Physics -informed State -space neural network Models (PSMs), a novel solution to achieving real-time optimization, flexibility, and fault tolerance in autonomous systems, particularly in transportdominated systems such as chemical, biomedical, and power plants. Traditional data -driven methods fall short due to a lack of physical constraints like mass conservation; PSMs address this issue by training deep neural networks with sensor data and physics -informing using components' Partial Differential Equations (PDEs), resulting in a physics -constrained, end -to -end differentiable forward dynamics model. Further, through two in silico experiments - a heated channel and a cooling system loop - we demonstrate that PSMs offer a more accurate approach than a purely data -driven model. In the former experiment, PSMs demonstrated significantly lower average root -mean -square errors across test datasets compared to a purely data -driven neural network, with reductions of 44 %, 48 %, and 94 % in predicting pressure, velocity, and temperature, respectively. Beyond accuracy, PSMs demonstrate a compelling multitask capability, making them highly versatile. In this work, we showcase two: supervisory control of a nonlinear system through a sequentially updated state -space representation and the proposal of a diagnostic algorithm using residuals from each of the PDEs. The former demonstrates PSMs' ability to handle constant and time -dependent constraints, while the latter illustrates their value in system diagnostics and fault detection.

42 ENGINEERING↗

DOE OSTI2020

Reactor Power Level Estimation by Fusing Multi-Modal Sensor Measurements

Estimates of the power level of a nuclear reactor based on measurements from an independent monitoring sensor system can help in the compliance verification of its declared operations. We present a three-level fusion method to estimate the power level of a nuclear reactor using features derived from infrared, electromagnetic, and acoustic sensor measurements collected in proximity to the reactor. Based on a simplified analytical model of the secondary coolant system of the reactor, we identify partial regression functions of the power level in terms of the temperature difference between inlet and outlet of coolant pipes, and the activity levels of four fans and four pumps, which are estimated as features from the sensor measurements. The power level estimator employs a combination of aggregate and complementary fusion steps at three levels to incorporate the multi-modal features in a structure that reflects the secondary cooling system and its partial regression functions. Using the measurements from a test campaign at an operational reactor, we show that this estimator achieves 3.47% or lower root mean square error under 5-fold cross validation. More generally, these results illustrate a progressive reduction in estimation error as additional modalities are appropriately incorporated, and that the fuser outperforms single modality features and their sub-combinations.

Rao, Nageswara↗