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At least 307 records · Page 17
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Acetonitrile Destruction and Fate of Organics in the Reverse Osmosis System at the ETF

The Hanford Site Effluent Treatment Facility (ETF) currently treats aqueous waste streams that include condensates from the 242-A evaporator, leachate from the Environmental Restoration Disposal Facility (ERDF), as well as laboratory wastes and, in the future, will treat liquid effluents from the Hanford Tank Waste Treatment and Immobilization Plant (WTP) and Integrated Disposal Facility (IDF) leachate. Liquid effluents from the WTP will have significant concentrations of acetonitrile. Acetonitrile is formed by reaction of nitrates and sugar in the WTP low activity waste (LAW) melters and is prevalent in the submerged bed scrubber (SBS) and wet electrostatic precipitator (WESP) liquid effluents from WTP off-gas treatment. When these liquids are concentrated in the WTP Effluent Management Facility (EMF) evaporator in the direct feed low activity waste (DFLAW) flow-sheet, testing has shown that the majority of the acetonitrile partitions to the evaporator condensate. Since the evaporator condensate is directed to the ETF, this creates a potential issue with the ETF waste acceptance criteria. Consequently, there is a need to validate flow-sheet assumptions on the fate of acetonitrile and other organics within the ETF. The present plan includes the addition of a steam stripper to the ETF to remove acetonitrile. There is, therefore, also a need to determine a suitable method to destroy acetonitrile in the overhead condensate stream from the new steam stripper. Washington River Protection Solutions, LLC (WRPS) previously contracted with Atkins and the Vitreous State Laboratory (VSL) of The Catholic University of America (CUA) to perform development and testing work to evaluate potential methods for destruction of acetonitrile in WTP secondary liquid effluents. Based on the results of that work, WRPS requested that follow-on testing be conducted to further evaluate acetonitrile destruction in the steam stripper condensate using ultraviolet oxidation (UV/OX) with persulfate. WRPS also requested testing to assess the rejection rate of organics in the reverse osmosis (RO) system installed in the ETF. This report presents the results from testing to address those needs.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2016

Fallon FORGE: Well Data, Geophysical Data, and Geologic Maps

The data is associated to the Fallon FORGE project and includes mudlogs for all wells used to characterize the subsurface, as wells as gravity, magnetotelluric, earthquake seismicity, and temperature data from the Navy GPO and Ormat. Also included are geologic maps from the USGS and Nevada Bureau of Mines and Geology for the Fallon, NV area.

13-36↗
DOE OSTI2025

A Novel Optical Instrument for On-Line Measurement of Particle Size Distribution—Application to Clean Coal Technologies

A flow cell is a critical measurement interface for many optical instruments. However, the flows are often sampled under harsh conditions, such as under high pressure and/or high temperature, in the presence of particles, moisture, vapors with high dew points or corrosive gases. Therefore, obtaining a high-optical-quality flow cell that does not perturb the measurement is a significant challenge. To address this challenge, we proposed a new flow cell that employs a unique laminar coaxial flow field (for the purge and sample flows). A test system was built to conduct particle size distribution (PSD) measurements with no sampling bias using a state-of-the-art analyzer (Malvern Panalytical Insitec). The results revealed that the measurement zone is well defined solely by the sample flow, and the optical windows are well protected by the purge flow, with minimal risk of any depositions from the sample flow. Using this flow cell, the Insitec can successfully measure PSD under high pressure and temperature under moist, corrosive conditions without generating any sampling bias. Importantly, we successfully applied this flow cell for on-line PSD measurement for the flue gas of a 100 kWth pressurized oxy-coal combustor operating at 15 bara.

Cheng, Mao (ORCID:0000000213273900)↗
DOE OSTI2020

Spent Crystalline Silicotitanate Storage Study

Washington River Protection Solutions is working to support initial production of immobilized low-activity waste (LAW) by feeding Hanford tank supernate from tank farms to the Hanford Waste Treatment and Immobilization Plant (WTP) LAW Facility. This goal incorporates the design of a Tank-Side Cesium Removal (TSCR) system, which filters tank waste supernate to remove suspended solids and then removes Cs by processing it through crystalline silicotitanate (CST) ion exchange media manufactured by Honeywell UOP, LLC. The 137 Cs-depleted product is intended to be sent to the WTP for vitrification. The Cs-loaded CST columns will be stored indefinitely, with a goal of eventual CST removal and treatment. Thus, the spent CST needs to be recoverable. The testing described herein looks to potential upset process conditions where CST storage may be required before various rinse steps are completed. This study evaluated upset conditions at three sequential processing steps envisioned for TSCR (feed, 0.1 M NaOH rinse, water rinse), and in-column drying with compressed air (normal end step) to assess impacts on the nature of the CST bed. Testing was conducted at the small scale (12-mL bed volume); simulated AP-105 tank waste was used as the feed. Following process disruption, the CST bed was dried in place at 70 °C. Post-dried CST bed physical properties (angle of repose, penetration depth, particle morphological changes) were measured to evaluate how CST moved and flowed. The testing is intended to provide a preliminary assessment of issues that may arise from desiccation of CST with the indicated salt solutions in place. Since these were small-scale tests, the processing conditions will not match full scale conditions exactly; however, the tests do provide insight into the impact of stopping processing at an earlier step than normal. Except for the feed that was dried in-place, all other process stop-conditions showed the CST bed flowed well after drying. At this small scale, CST beds would not present an issue for retrievability. The feed that was dried in place had solidified into a rock-hard monolith with no movement possible. Samples had to be chipped from the surface.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2014

Comparison of electrical capacitance tomography and gamma densitometer measurement in viscous oil-gas flows

Multiphase flow is a common occurrence in industries such as nuclear, process, oil and gas, food and chemical. A prior knowledge of its features and characteristics is essential in the design, control and management of such processes due to its complex nature. Electrical Capacitance Tomography (ECT) and Gamma Densitometer (Gamma) are two promising approaches for multiphase visualization and characterization in process industries. In two phase oil and gas flow, ECT and Gamma are used in multiphase flow monitoring techniques due to their inherent simplicity, robustness, and an ability to withstand wide range of operational temperatures and pressures. High viscous oil (viscosity > 100 cP) is of interest because of its huge reserves, technological advances in its production and unlike conventional oil (oil viscosity < 100 cP) and gas flows where ECT and Gamma have been previously used, high viscous oil and gas flows comes with certain associated concerns which include; increased entrainment of gas bubbles dispersed in oil, shorter and more frequent slugs as well as oil film coatings on the walls of flowing conduits. This study aims to determine the suitability of both devices in the visualization and characterization of high-viscous oil and gas flow. Static tests are performed with both devices and liquid holdup measurements are obtained. Dynamic experiments were also conducted in a 1 and 3 inch facility at Cranfield University with a range of nominal viscosities (1000, 3000 and 7500 cP). Plug, slug and wavy annular flow patterns were identified by means of Probability Mass Function and time series analysis of the data acquired from Gamma and ECT devices with high speed camera used to validate the results. Measured Liquid holdups for both devices were also compared.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2021

Flow behavior characterization of biomass Feedstocks

With the advancement of renewable energy, the processing and handling of biomass feedstocks has drawn enormous research interest. The key to economically viable and operationally reliable biomass handling processes involves a complete understanding of the flow behavior of different feedstocks as functions of the inherent critical material properties environmental conditions, and critical processing parameters. This review introduces the basic principles and methods in bulk solids flow and highlights recent efforts to understand the flow behavior of biomass feedstocks. The effects of inherent properties, environmental parameters, and handling equipment on the flow behavior of biomass feedstocks are presented. Particle size, shape, moisture, consolidation stress, temperature, storage time at rest, chemical treatment, and the material and geometry of the handling equipment all substantially influence biomass flowability. The limitations of current studies and the potential methods to overcome them are presented. Finally, an outlook for future research effort is provided, with proposed opportunities for improving the characterization of biomass flow.

Bulk solids testing↗
DOE OSTI2014

Investigation of ALEGRA shock hydrocode algorithms using an exact free surface jet flow solution.

Computational testing of the arbitrary Lagrangian-Eulerian shock physics code, ALEGRA, is presented using an exact solution that is very similar to a shaped charge jet flow. The solution is a steady, isentropic, subsonic free surface flow with significant compression and release and is provided as a steady state initial condition. There should be no shocks and no entropy production throughout the problem. The purpose of this test problem is to present a detailed and challenging computation in order to provide evidence for algorithmic strengths and weaknesses in ALEGRA which should be examined further. The results of this work are intended to be used to guide future algorithmic improvements in the spirit of test-driven development processes.

Hanks, Bradley Wright.↗
DOE OSTI2017

Current Efforts in Immobilized Low-Activity Waste Glass Testing to Support the Hanford Site Integrated Disposal Facility - 17119

Cleanup plans for Hanford site high-level radioactive mixed tank waste calls for separating the waste into high-level waste (HLW) and low-activity waste (LAW) fractions. The fractions will be vitrified separately at the Hanford Tank Waste Treatment and Immobilization Plant (WTP). The HLW glass will be sent to an offsite geological disposal facility while the immobilized low-activity waste (ILAW) glass will be disposed at the onsite Integrated Disposal Facility (IDF). In order to inform models used to predict the performance of ILAW glass at IDF, it is necessary to understand the corrosion behavior of the glass. In this paper, we discuss tests that account for the effects of 1) solution chemistry, 2) the ion exchange reaction, and 3) secondary phase formation on the glass dissolution rate. To quantify the effects of solution chemistry, specifically changes in pH, T, and Si concentration, the single-pass flow-through (SPFT) test method is applied. A designed set of these tests results in a set of kinetic rate law parameters that are used in a glass dissolution rate law based on transition-state theory. Furthermore, for SPFT tests with relatively high concentrations of Si, an ion exchange rate is provided. Additionally, through tests such as the pressurized unsaturated flow (PUF) test method, a suite of secondary phases can be compiled. The collection of kinetic rate law parameters, the ion exchange term, and the suite of secondary phases are provided to IDF performance assessment (PA) modelers. Lastly, we present a description of the efforts made to verify and validate the use of these parameters and secondary phases through the use of a field lysimeter present at the Hanford site. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2023

Development of Microwave Resonant Cavity Transducer Recalibration Procedures

We are investigating a microwave resonant cavity transducer for flow sensing in the vessel of a high temperature fluid advanced reactor (AR), such as a molten salt cooled reactor (MSCR) or a sodium fast reactor (SFR). This transducer is a hollow metallic cylindrical cavity, with one of the flat walls of the cylinder flexible enough to undergo microscopic deflection due to dynamic fluid pressure. Membrane deflection leads to a shift in the microwave resonant frequency, which can be detected with a spectrum analyzer. We have performed a preliminary proof-of-principle test of flow sensing in high temperature liquid sodium in environment. The liquid sodium setup consists of a cylindrical vessel with a center feed line, where a transducer inserted through the top cap of the vessel measures velocity of the impinging liquid jet. For this test, we have developed a cylindrical resonator, which was machined from stainless steel 316 and electroplated with silver on the interior surfaces. Inner diameter of the cylindrical cavity is 22.2 mm, and the thin wall is approximately 200µm thick. The cavity was excited through a WR-42 waveguide through a subwavelength hole on the side of the wall of the cylinder in the TE 011 mode with resonant frequency f ≈ 17.8GHz. Sodium flow rate sensing study was performed in a liquid sodium vessel at 340°C temperature and ambient pressure. The flow rate was changed by varying sodium pump power, and a frequency shift of several hundred KHz was observed. From the measurements, we observed significant scatter in high temperature liquid sodium at low flow velocity values. Our hypothesis is that this is caused by temperature drift in the liquid, which results in thermal expansion of the cavity and a drift in the resonator frequency. In this report, we investigate temperature dependence of the resonant frequency through development of analytic models and preliminary analysis of experimental data. In addition, we develop a procedure for compensation for temperature drift during flow sensing.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2017

Nuclear thermal source transfer unit, post-blast soil sample drying system

Los Alamos National Laboratory states that its mission is “To solve national security challenges through scientific excellence.” The Science Undergraduate Laboratory Internship (SULI) programs exists to engage undergraduate students in STEM work by providing opportunity to work at DOE facilities. As an undergraduate mechanical engineering intern under the SULI program at Los Alamos during the fall semester of 2016, I had the opportunity to contribute to the mission of the Laboratory while developing skills in a STEM discipline. I worked with Technology Applications, an engineering group that supports non-proliferation, counter terrorism, and emergency response missions. This group specializes in tool design, weapons engineering, rapid prototyping, and mission training. I assisted with two major projects during my appointment Los Alamos. The first was a thermal source transportation unit, intended to safely contain a nuclear thermal source during transit. The second was a soil drying unit for use in nuclear postblast field sample collection. These projects have given me invaluable experience working alongside a team of professional engineers. Skills developed include modeling, simulation, group design, product and system design, and product testing.

42 ENGINEERING↗
DOE OSTI2023

Demonstration of Microwave Cavity Transducer Performance in High Temperature Fluid Flow Sensing: Development of Microwave Cavity Flow Meter for Advanced Reactor High Temperature Fluids

We are investigating a microwave resonant cavity transducer for flow sensing in the vessel of a high temperature fluid advanced reactor (AR), such as a molten salt cooled reactor (MSCR) or a sodium fast reactor (SFR). This transducer is a hollow metallic cylindrical cavity, with one of the flat walls of the cylinder flexible enough to undergo microscopic deflection due to dynamic fluid pressure. Membrane deflection leads to a shift in the microwave resonant frequency, which can be detected with a spectrum analyzer. We have performed a preliminary proof-of-principle test of flow sensing in high temperature liquid sodium in environment, which is similar to that of an advanced reactor. The liquid sodium setup consists of a cylindrical vessel with a center feed line, where a transducer inserted through the top cap of the vessel measures velocity of the impinging liquid jet. For this test, we have developed a cylindrical resonator, which was machined from stainless steel 316 and electroplated with silver on the interior surfaces. Outer diameter of the cylindrical cavity is approximately 3cm, and the thin wall is approximately 200µm thick. We have also developed and insertion probe consisting of a 50cm WR-42 brass waveguide enclosed in a protective SS316 tube. The cavity was excited through a WR-42 waveguide through a subwavelength hole on the side of the wall of the cylinder in the TE 011 mode with resonant frequency f ≈ 17.8GHz. As a calibration experiment, we have assembled a water vessel with a center feed, and with dimensions similar to those of the liquid sodium setup. Frequency shift of the cavity spectral response was obtained at room temperature and ambient pressure by gradually increasing water flow rate from 0 to 25GPM (gallons per minute). Corresponding monotonic increase of resonant frequency by several hundred KHz was observed. Next, a sodium flow rate sensing study was performed in a liquid sodium vessel at 340° C temperature and ambient pressure. The flow rate was changed by varying sodium pump power, and a frequency shift of several hundred KHz was observed.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2013

Monitoring a large-volume injection at Cranfield, Mississippi—Project design and recommendations (SECARB Integrated Results Study)

Injection and storage of 4 million metric tons of CO 2 have been monitored to observe multiphase fluid flow, to test technologies, to document permanence of storage, and to advance techniques for capacity estimation. The injection interval is the 3000-m-deep fluvial Tuscaloosa Formation at a structural closure that defines the Cranfield oilfield. Tests were conducted in the oil-producing area as well as in the downdip brine aquifer. These tests assessed the feasibility, operation, and sensitivity ofmonitoring using a selection oftools in the vadose zone, in the shallow groundwater, above the injection zone, and within the injection zone. Although each monitoring approach merits a separate, detailed analysis, this paper assesses the success of the overall strategy for monitoring and presents an overview of conclusions from multiple data sets. Comparisons of modeled to observed reservoir response highlight the difficulties encountered in uniquely explaining measured pressure and fluid saturation measurements at interwell and field scales. Results of this study provide a cautionary note to regulatory and accreditation end users about the feasibility of obtaining unique and quantitative matches between fluid flow models and field measurements.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2016

Extracting Uranium from Seawater: Promising AI Series Adsorbents

A new series of adsorbents (AI10 through AI17) were successfully developed at ORNL by radiation induced graft polymerization (RIGP) of acrylonitrile (AN) and vinylphosphonic acid (VPA) (at different mole to mole ratios) onto high surface area polyethylene fiber, with high degrees of grafting (DOG) varying from 110 to 300%. The grafted nitrile groups were converted to amidoxime groups by reaction with 5 wt % hydroxylamine at 80 °C for 72 h. The amidoximated adsorbents were then conditioned with 0.44 M KOH at 80 °C followed by screening at ORNL with prescreening brine spiked with 8 ppm uranium. Uranium adsorption capacities in prescreening ranged from 171 to 187 g-U/kg-ads irrespective of percent DOG. The performance of the adsorbents with respect to uranium adsorption in natural seawater was also investigated using flow-throughcolumn testing at the Pacific Northwest National Laboratory (PNNL). Three hours of KOH conditioning led to higher uranium uptake than 1 h of conditioning. The adsorbent AI11, containing AN and VPA at the mole ratio of 3.52, emerged as the potential candidate for the highest uranium adsorption (3.35 g-U/kg-ads.) after 56 days of exposure in seawater flow-through-columns. The rate of vanadium adsorption over uranium linearly increased throughout the 56 days of exposure. The total mass of vanadium uptake was ~5 times greater than uranium after 56 days.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2018

Permeation testing of thermal power plant cooling water impacts of Graphite Oxide (GO)/polymer membranes

The purpose of this project was to investigate how thermoelectric power plant cooling water impacts the energy demands, permeance, and ion rejection of GO/polymer membranes using extended permeation testing. Treatment of cooling tower blowdown water is challenging since this water contains scalants (e.g.: silica, calcium sulfate, calcium carbonate) which can precipitate on membranes, decreasing membrane efficiency and lifetime. In this collaboration with EPRI and a Southwestern US utility, the performance of GO/polymer membranes in desalinating cooling tower blowdown water from three natural-gas fueled power plants was evaluated. Results of cross-flow desalination test durations of three to four weeks demonstrated the long-term stability of the membranes. GO/polymer desalination membranes were shown to tolerate drinking-water level chlorination, which could reduce capital and operational costs. Biofouling and scale formation were minimal on the GO surface, suggesting that industry standard intensive cleaning steps could be reduced. Results also demonstrated pressure-tunable rejection which would allow treat-to-need water recycling, thus likely reducing energy costs for these membranes. Further development of biofouling and scaling resistant desalination membranes could lead to reduced cost for water treatment, potentially allowing for greater use of non-traditional water supplies for thermoelectric power plants.

Biedermann, Laura↗
DOE OSTI2022

EGS Collab Experiment 3: 4100 Tensile Stimulation and Thermal Circulation Testing

These data and test descriptions are from a set of primarily tensile hydraulic-fracture stimulations in wells E2-TC and E2-TU and a subsequent chilled water circulation test conducted by injecting in well E2-TU on the 4100 level of the Sandford Underground Research Facility (SURF). Stimulations were carried out between April and May of 2022. The thermal circulation test ran semi-continuously from May 19 through August 26, 2022, though chilled water injection began on June 3. More information about the test, rationale, and processing of data is available on the EGS Collab project page, which is linked below.

15 GEOTHERMAL ENERGY↗
DOE OSTI2026

Thermal property characterization of phase change materials in building applications: A systematic review of fundamentals, recent progress, and future directions

Phase change materials (PCMs) can reduce building peak loads and enable demand-responsive thermal energy storage (TES), but their deployment depends on reliable measurement and interpretation of thermal properties across laboratory, intermediate, and application scales. Here, this review systematically examines characterization methods, testing protocols, and recent advances for neat PCMs and PCM composites, emphasizing thermal conductivity, enthalpy-related properties (phase change temperature, latent heat, specific heat), and cycling stability. For thermal conductivity, we compare steady-state and transient techniques and note limitations when phase transition and contact resistance affect measurements. For enthalpy–temperature characterization, we discuss differential scanning calorimetry together with intermediate- and bulk-scale methods, including T-history, heat flow meter testing, and three-layer calorimetry (3LC), to generate application-relevant enthalpy–temperature profiles. Cycling stability is organized into four experimental families: thermoelectric–air, fully thermoelectric, water-bath, and in situ chamber approaches, with attention to separating reversible supercooling from true degradation such as phase segregation. We highlight emerging noncontact diagnostics, including infrared thermography and embedded sensing, for spatially resolved validation and multiscale interpretation. Finally, we review the growing use of AI and machine learning for property prediction, inverse characterization from experimental signals, and real-time state estimation in building-integrated TES. Key needs include harmonized protocols, interlaboratory benchmarking, uncertainty reporting, and metadata-rich datasets to accelerate reproducible PCM qualification for grid-flexible buildings.

AI↗
DOE OSTI2017

One Step Hydrogen Generation Through Sorption Enhanced Reforming

One-step hydrogen generation, using Sorption Enhanced Reforming (SER) technology, is an innovative means of providing critical energy and environmental improvements to US manufacturing processes. The Gas Technology Institute (GTI) is developing a Compact Hydrogen Generator (CHG) process, based on SER technology, which successfully integrates previously independent process steps, achieves superior energy efficiency by lowering reaction temperatures, and provides pathways to doubling energy productivity with less environmental pollution. GTI’s prior CHG process development efforts have culminated in an operational pilot plant. During the initial pilot testing, GTI identified two operating risks- 1) catalyst coating with calcium aluminate compounds, 2) limited solids handling of the sorbent. Under this contract GTI evaluated alternative materials (one catalyst and two sorbents) to mitigate both risks. The alternate catalyst met performance targets and did not experience coating with calcium aluminate compounds of any kind. The alternate sorbent materials demonstrated viable operation, with one material enabling a three-fold increase in sorbent flow. The testing also demonstrated operation at 90% of its rated capacity. Lastly, a carbon dioxide co-production study was performed to assess the advantage of the solid phase separation of carbon dioxide- inherent in the CHG process. Approximately 70% lower capital cost is achievable compared to SMR-based hydrogen production with CO2 capture, as well as improved operating costs.

08 HYDROGEN↗
DOE OSTI2022

MAGNETICALLY SUSPENDED CANNED ROTOR PUMPS FOR THE INTEGRAL MOLTEN SALT REACTOR

This project developed a molten salt pump design for small modular reactors, concentrated solar, and Gen IV nuclear reactors with a magnetically levitated rotor that can operate at temperatures of up to 700 °C. This eliminates the need for rotating seals and roller element bearings which require maintenance and are prone to failure. The pump design is also more compact than existing molten salt pump designs which require long shafts to thermally isolate the electric motor. The aims of the project are to: 1) design and test the molten salt pump, 2) develop and test a high temperature position sensor needed for magnetic bearing control, and 3) develop and test high temperature coil fabrication methods for electric motor and magnetic bearing fabrication. To develop the high temperature coils, conductor materials were analyzed for oxidation, diffusion, cladding, and resistivity. Of the candidate conductor materials that met the requirements, silver was chosen. The long-term impact of radiation on silver resistivity was analyzed by developing a model of a generic molten salt fast reactor to model the conductor irradiation in worst case scenarios. The analysis showed that increased resistivity due to transmutation of silver decreases exponentially with the reactor reflector thickness. Different electrical insulation materials were tested and the final high temperature coils developed were able to withstand conductor to ground voltages up to 1800 V before insulation breakdown. Magnetic bearings require high-precision high-speed measurements of the rotor position to operate. Current commercial position sensors can only operate up to 550 °C so a novel position sensor was developed that can operate up to 800 °C. These sensors were also designed to measure the position of the metallic rotor through a thin metallic corrosion barrier that protects that coils, insulation, and magnetic cores so that the salt containment barrier does not have any penetrations. The high-temperature sensor was tested and had comparable performance to commercially available inductive position sensors. The sensor design and signal processing has led to several invention disclosures. The magnetically levitated molten salt pump design was completed and analyzed. The chloride salt test loop at Oak Ridge National Laboratory was chosen to test the pump and the pump hydraulics and power were designed for the test loop flow and pressure requirements. Classes of motor designs that do not utilize permanent magnetic were considered for the high-temperature motor. After extensive analysis of their performance, a synchronous reluctance motor was chosen for the pump. The design was refined and analyzed to optimize performance. The magnetic bearings were designed to meet the force and frequency requirements necessary to levitate the rotor and reject disturbances from rotor imbalance, motor forces, and hydraulic forces. Compliant mounts for the position sensors were designed that would not damage the ceramic sensor components and maintain sensor alignment over a wide temperature range. A thermal hydraulic analysis of the molten salt coolant flow used to cool the rotor and stator was performed to ensure that the maximum temperature in the rotor and stator will not exceed 725 °C. The corrosion barrier and casing were designed to maintain the salt fluid boundary by using compliant features to absorb large expansion mismatches due to different coefficients of thermal expansion (CTE). Finally, the salt drain and fill systems were designed along with the pump support structure, integration with the test loop, and thermal insulation and heating. Corrosion barrier fabrication experiments were performed to assess using laser cladding to apply a sub-millimeter corrosion barrier to the surface of a Fe-Co-V magnetic core material. The cladding method showed minimal mixing between materials at their interface and withstood temperature cycling without damage to the cladding. The technology commercialization is focused on the high-temperature position sensors and there has been significant interest from the nuclear industry in utilizing these sensors along with some interest from the aerospace industry. The project also led to a research collaboration with a fusion energy industrial partner to study barriers to scaling the pump design from the kW size to the MW size. This research collaboration will also study methods to create high-temperature coils that have conductor to ground breakdown voltages above 5 kV. The successful development of high-temperature electromagnetic coils and high-temperature position sensors greatly increases the temperature limits for electromagnetic devices that don’t rely on permanent magnets. This includes electric motors, magnetic bearings, linear actuators, rotary position and velocity sensing, actuated valves, and generators to name a few. This will fill a current need in molten salt reactors, concentrated solar, and fusion energy for these critical peripheral devices needed for practical reactor designs that do not currently have commercial solutions.

Hines, J Wesley↗