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DOE OSTI2025

Technical Assessment of Off-Gas System Technologies for Potential Use in Molten Salt Reactors

Molten salt reactors (MSRs) are a class of Generation IV advanced reactor technologies aimed to enhance and improve the safety, fuel utilization and cost-effectiveness of nuclear power generation. MSR concepts are based on using a molten salt mixture as a primary nuclear reactor coolant, while the fuel can be either directly dissolved in the coolant (i.e., fluid-fueled) or can be in a separate solid form (i.e., salt-cooled solid-fueled). MSRs can be operated in either thermal or fast neutron spectra, as simple fissile convertors, or breeder reactors (e.g., utilizing both fissile and fertile fuels), as well as accelerator-driven sub-critical reactors or transuranic element burners. Operation of MSRs will necessitate management and treatment of the off-gas streams released to the headspace of the reactor where, in some designs, a cover gas can be circulated to remove certain fission products and maintain an inert atmosphere. An inert MSR cover gas swept over or sparged into the salt will confine radionuclides emerging from the free surface, including radioactive noble and non-noble gases, aerosols, and volatile species. The elements and compounds of these species will have a wide range of thermochemical and physical properties, some of which will decay to different products in the off-gas stream. Therefore, system components used to manage and treat MSR off-gas streams will need to be robust under dynamic reactor and chemistry conditions to support adequate reactor performance by managing the composition and species in the salt coolant and cover gas space. Off-gas system components would perform as a radionuclide boundary to the reactor vessel and a primary means for preventing radionuclide release; therefore, they are of high safety significance for MSR operations. This report reviews various technologies and materials for potential implementation in the design of an MSR off-gas system per a general conceptual framework. The reviewed technologies operate based on scrubbing, capture, delay, or separation of species in the off-gas stream. These include molten hydroxide scrubbers, solid sorbents, delay off-gas systems, particle traps, and cryogenic distillation. Since aspects of an off-gas system will be design-specific, the approach is to provide general discussions on attributes of these technologies and materials, including target off-gas stream species, operational parameters and conditions of importance to decontamination factors, implementation maturity, system component monitoring, potential off-normal conditions and considerations for waste products. The information aims to support the U.S. Nuclear Regulatory Commission in their safety evaluations for MSR designs.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2020

Validation and Parametric Investigations Using a Lumped Thermal Parameter Model of an Internal Permanent Magnet Motor: Preprint

One of the key challenges for the electric vehicle industry is to develop high-power-density electric motors. Achieving higher power density requires efficient heat removal from inside the motor. In order to improve thermal management, a multi-physics modeling framework that is able to accurately predict the behavior of the motor, while being computationally efficient, is essential. This paper first presents a detailed validation of a Lumped Parameter Thermal Network (LPTN) model of an Internal Permanent Magnet (IPM) synchronous motor within the commercially available Motor-CAD® modeling environment. The IPM motor’s stator is studied at steady state, and winding losses are generated by a constant DC current. The validation is based on temperature comparison with experimental data and with more detailed Finite Element Analysis (FEA). All critical input parameters of the LPTN are considered in detail for each layer of the stator, especially the contact resistances between the impregnation, liner, laminations and housing. Finally, a sensitivity analysis for each of the critical input parameters is provided. A maximum difference of 4% - for the highest temperature in the slot windings and the end windings - was found between the LPTN and the experimental data. Comparing the results from the LPTN and the FEA model, the maximum difference was 2% for the highest temperature in the slot windings and end windings. As for the LTPN sensitivity analysis, the thermal parameter with the highest sensitivity was found to be the liner-to-lamination contact resistance. The latter is often ignored in the literature, whereas its impact on temperature rise was found to be more significant than any other contact resistance within the stator.

ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2023

Addressing Consequence within Operational Risk: An Approach for Understanding an Organization’s Unique Infrastructure Environment

The endeavor of tackling operational risk focused on consequences is challenging even for the most resourced entity but can be advanced though a simplified approach: identifying, binning, and prioritizing the infrastructure environment. While no two entities within a single element of the 16 critical infrastructure sectors are exactly alike when it comes to risk, there is a basic process to move toward a greater understanding of operational risk through becoming more informed about the infrastructure landscape in which the entity exists. The process starts with bringing internal and external stakeholders and subject matter experts together to analyze key areas such as Information Technology (IT) and Operational Technology (OT) components and points of convergence, analyzing internal and external cyber and physical dependencies, accounting for explosive growth in devices and wireless technology, and leveraging the contributions of people inside and outside the operational environment. Attaining a common understanding of the infrastructure landscape as part of addressing consequences within operational risk is not easy to do or resource light, but the process outlined provides the framework to further any entity’s efforts in this space.

99 GENERAL AND MISCELLANEOUS↗

DOE OSTI1995

Nuclear Safety [Vol. 36, No. 2, July-December 1995]

Nuclear Safety is a journal that covers significant issues in the field of nuclear safety. Its primary scope is safety in the design, construction, operation, and decommissioning of nuclear power reactors worldwide and the research and analysis activities that promote this goal, but it also encompasses the safety aspects of the entire nuclear fuel cycle, including fuel fabrication, spent-fuel processing and handling, and nuclear waste disposal, the handling of fissionable materials and radioisotopes, and the environmental effects of all these activities. Table of Contents for this issue follows. THE CHORNOBYL ACCIDENT: 195 The Chornobyl Accident Revisited, Part III: Chernobyl Source Term Release Dynamics and Reconstruction of Events During the Active Phase, A. R. Sich; GENERAL SAFETY CONSIDERATIONS: 218 Second ANS Workshop on the Safety of Soviet-Designed Nuclear Power Plants, R. A. Bari; 234 Elements of a Nuclear Criticality Safety Program, C. M. Hopper; 243 Rickover, Excellence, and Criticality Safety Programs, R. E. Wilson; ACCIDENT ANALYSIS: 249 Transient Analysis of the PIUS Advanced Reactor Design with the TRAC-PF1/MOD2 Code, B. E. Boyack, J. L Steiner, S. C. Harmony, H. J. Stumpf, and J. F. Lime; 278 The Hierarchy-By-Interval Approach to Identifying Important Models that Need Improvement in Severe-Accident Simulation Codes, T. J. Heames, M. Khatib-Rahbar, J. E. Kelly, R. P. Jenks-Johnson, and Y.-S. Chen; 290 RELAP5/MOD3 Code Coupling Model, R. P. Martin; 299 Missiles Caused by Severe Pressurized-Water Reactor Accidents, R. Krieg; DESIGN FEATURES: 310 Validation of COMMIX with Westinghouse AP-600 PCCS Test Data, J. G. Sun, T. H. Chien, J. Ding, and W T. Sha; ENVIRONMENTAL EFFECTS: 321 Spent Nuclear Fuel Characterization for a Bounding Reference Assembly for the Receiving Basin for Off-Site Fuel, S. D. Kahook, R. L. Garrett, L. R. Canas, and M J. Beckum; OPERATING EXPERIENCES: 332 Reactor Shutdown Experience, Compiled by J. W. Cletcher; U.S. NUCLEAR REGULATORY COMMISSION INFORMATION AND ANALYSES: 335 Reactor Coolant System Blowdown at Wolf Creek on September 17, 1994, J. V. Kauffman and S. L. Israel; RECENT DEVELOPMENTS: 344 Reports, Standards, and Safety Guides, D. S. Oueener; 349 Proposed Rule Changes as of June 30, 1995; ANNOUNCEMENTS: 320 Symposium on Acceptability of Risk From Radiation—Application to Manned Space Flight; 320 24th DOE/NRC Nuclear Air Cleaning and Treatment Conference; 361 Radiation Biology and Radiation Protection— Modern Developments and Tendencies in Radiation Biology; 362 1997 IEEE Sixth Conference on Human Factors and Power Plants; 354 The Authors; 360 Reviewers of Nuclear Safety, Vol. 36.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2022

Selective Sulfidation for Rare Earth Element Separation

Rare earth metals and compounds are critical components of advanced materials for energy, structural alloys, and transportation. These low-tonnage elements are sourced together as by- and co-products, and presently require complete hydrometallurgical dissolution followed by liquid–liquid separation for their isola- tion and production. There is great interest in developing alternatives to those hydrometallurgical processes in order to limit the environmental impact of rare earth element supply. Herein, we present selective sulfidation as a novel, high- temperature alternative to facilitate physical separation of rare earth by- and co- product elements. We explore the thermodynamics of rare earth oxide sulfidation with elemental sulfur, and discuss the role of carbon in controlling sulfidation selectivity. We apply these findings to the demonstration of selective sulfidation for iron-rare earth and lanthanide-lanthanide separations.

36 MATERIALS SCIENCE↗

DOE OSTI2024

Critical mineral source potential from oil & gas produced waters in the United States

The volume of produced water, a by-product of oil & gas operations and other energy processes, has been growing across the United States (U.S.) along with the need to manage or recycle this wastewater. Produced water contains many naturally occurring elements of varying concentrations, including critical minerals which are essential to the clean energy transition. However, the current understanding of critical mineral concentrations in produced water and the associated volumes across the U.S. is limited. This study has assessed available databases and literature to gain insight into the presence and concentration of five high priority critical minerals, namely cobalt, lithium, magnesium, manganese, and nickel. The U.S. Geological Survey's National Produced Waters Geochemical Database was the main data source used for determining average critical mineral concentrations in produced water from the major oil and gas reservoirs in the U.S. The volumes of produced water for these major reservoirs were coupled with these concentrations to provide insights into where critical minerals are likely to have high abundance and therefore more recovery options. The analysis indicated the highest recovery potential for lithium and magnesium from produced water in the Permian basin and the Marcellus shale region. However, these assessments should be considered conservative due to the limited availability of reliable concentration data. Finally, it is expected more critical mineral recovery options could emerge with comprehensive characterization data from more recent and representative sources of produced water.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2026

Carbon ore, rare earth, and critical minerals (core-cm) assessment of san juan and raton coal basins: what is the future potential of coal in the san juan and raton basins, new mexico and colorado

This report summarizes results from the CORE-CM project in the San Juan and Raton basins of New Mexico and Colorado and ultimately begins to address what is the future of coal in the San Juan and Raton basins. The objective of this project was to determine the nonfuel carbon-based products (CBP), critical minerals, and rare earth elements (REE) potential in coal and related stratigraphic units in the San Juan and Raton basins and adjacent areas. This project delineated favorable geologic terrains and priority areas containing potential CBP, critical minerals, and REE deposits for the DOE mandate, which also is a priority of the NMBGMR and state of New Mexico. This project is important to the state because CBP, critical minerals, and REE resources must be identified before land use decisions are made by government officials. Future mining of CBP, critical minerals, and REE will directly benefit the economy of New Mexico. Furthermore, it is crucial to re-establish a domestic source of critical minerals and REE in the U.S. to help secure the nation’s clean energy future, to reduce the vulnerability of the U.S. to material shortages related to national defense, and to maintain our global technical and economic competitiveness. In addition to these benefits, students at New Mexico Institute of Mining and Technology (NMT) and San

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2023

Characterization and Recovery of Critical Metals from Municipal Solid Waste Incineration Ashes

The dependence on international supplies and lack of diverse supplies of critical materials (such as rare earth elements, REEs) have prompted the US to explore new sources and develop environmentally friendly technologies for critical metal extraction, processing, and manufacturing. Secondary wastes have been explored for the recovery of REEs. Municipal solid waste (MSW) is a large solid waste stream and may constitute the largest resource for REEs and other critical metals; yet its incineration ashes (MSWI ashes) have received limited attention in terms of critical metal recovery. On the other hand, management of MSWI ashes also presents significant challenges both operationally and financially, such as landfill costs, volume reduction, and contaminant immobilization. To address the challenges associated with the management of and resource recovery from MSWI ashes, this project developed a closed-loop, integrated, scalable, and environmentally friendly waste management and resource recovery system. This system is characterized with maximum recovery of REEs, production of additional salable products, minimal production of secondary waste, and high immobilization of heavy metal contaminants.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2026

Electronic Waste (E-Waste) Recycling: Barriers and Opportunities for State, Local, and Tribal Governments

Electronic waste, or e-waste, encompasses end-of-life electrical and electronic equipment, including computers, monitors, televisions, printers, cell phones, household appliances with electronic components, and small consumer devices containing batteries or circuitry. E-waste is one of the fastest-growing components of the U.S. waste stream, with nearly 8 million tons generated in 2022. E-waste presents two related public-interest considerations. First, e-waste contains economically and strategically important materials: base metals (copper, aluminum, iron, steel), precious metals (gold, silver, platinum group metals), and critical materials such as rare earth elements, gallium, and indium that appear on the U.S. Geological Survey's (USGS) 2025 List of Critical Minerals. Second, many electronic devices contain hazardous constituents - including lead, mercury, cadmium, and brominated flame retardants - as well as rechargeable batteries that can pose fire risks during handling. Effective management of these constituents helps protect workers, communities, and the environment. In the United States, it is estimated that less than 20% of e-waste is formally collected and recycled, leaving over 6 million tons landfilled or otherwise unrecovered. This fact sheet provides state and local decision-makers an overview of (1) e-waste composition and recoverable materials, (2) technology pathways used to recover those materials, and (3) examples of operational and partnership structures used to provide e-waste recycling capacity in the United States. It is intended to complement existing collection-program guidance available through U.S. Environmental Protection Agency (EPA) and other sources.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2024

Surrogate modeling of the leaching process in a rare earth elements recovery plant

The data are summarized in the slides for a poster as presented at the 2024 AIChE annual meeting in San Diego, California, USA. The slides summarize our work on the PrOMMiS project over the past year. The slides describe the systematic design and optimization of a flowsheet for the recovery of critical minerals and rare earth elements. Then, it summarizes the results of our benchmarking of surrogate modeling methodologies for the optimization of these flowsheets.

Fardis, Dimitrios↗

DOE OSTI2021

Critical review of functionalized silica sorbent strategies for selective extraction of rare earth elements from acid mine drainage

We report the ubiquitous and growing global reliance on rare earth elements (REEs) for modern technology and the need for reliable domestic sources underscore the rising trend in REE-related research. Adsorption-based methods for REE recovery from liquid waste sources are well-positioned to compete with those of solvent extraction, both because of their expected lower negative environmental impact and simpler process operations. Functionalized silica represents a rising category of low cost and stable sorbents for heavy metal and REE recovery. These materials have collectively achieved high capacity and/or high selective removal of REEs from ideal solutions and synthetic or real coal wastewater and other leachate source. These sorbents are competitive with conventional materials, such as ion exchange resins, activated carbon; and novel polymeric materials like ion-imprinted particles and metal organic frameworks (MOFs). This critical review first presents a data mining analysis for rare earth element recovery publications indexed in Web of science, highlighting changes in REE recovery research foci and confirming the sharply growing interest in functionalized silica sorbents. A detailed examination of sorbent formulation and operation strategies to selectively separate heavy (HREE), middle (MREE), and light (LREE) REEs from the aqueous sources is presented. Selectivity values for sorbents were largely calculated from available figure data and gauged the success of the associated strategies, primarily: (1) silane-grafted ligands, (2) impregnated ligands, and (3) bottom-up ligand/silica hybrids. These were often accompanied by successful co-strategies, especially bite angle control, site saturation, and selective REE elution. Recognizing the need to remove competing fouling metals to achieve purified REE “baskets,” we highlight techniques for eliminating these species from acid mine drainage (AMD) and suggest a novel adsorption-based process for purified REE extraction that could be adapted to different water systems.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

From Quantum to Classical: Sensing Materials, Methods, and Platforms for Energy

This presentation covers several ongoing sensors projects at NETL, including the use of quantum sensors for energy sector applications (e.g. infrastructure monitoring, critical metal detection, grid modernization) as well as NETL-developed materials and platforms for detecting economically critical metals including rare earth elements, cobalt, and aluminum. Taken together, these projects demonstrate NETL's leadership in unleashing American energy through the development of high performance sensors for reliable energy production and consumption.

critical minerals↗

DOE OSTI2023

Probabilistic Multi-Hazard Performance Assessment of Concrete Structures in Nuclear Installations

Concrete structures in nuclear installations are subject to time-dependent degradation mechanisms that can deteriorate their physical and mechanical properties, potentially exacerbating the risk of structural failure under external forces such as a seismic event. Previous research has extensively investigated the seismic response of nuclear concrete structures and the associated risk, as well as their effect on structural components safety margins. However, substantial work is still necessary to incorporate concrete aging effects into such evaluations. In fact, most models in the literature assume pristine concrete conditions and do not account for the impact of aging on the structural components’ fragility curves. This work identifies relevant time-dependent degradation mechanisms and provides simplified models to predict the the evolution of key material properties based on data from the literature. Namely, this work focuses on the aging effects of corrosion, alkali–silica reaction (ASR), and irradiation on reinforced concrete within US Department of Energy (DOE) nuclear facilities and nuclear power plants (NPP) structures. Furthermore, degradation models based on literature data are presented that define the relationship between probabilistic material properties and the concrete’s age. In this work, sampled material properties served as input for a simplified finite element model (FEM) of a critical nuclear structural system, with the output of the FEM being the seismic response for a given ground motion. The results of the FEM were then used within a probabilistic performance assessment with a statistically significant number of samples. The research presented herein addresses the detrimental effects of hazards caused by natural phenomena on deteriorated concrete elements of nuclear installations. This work directly benefits the safety analysis performed on US DOE/ National Nuclear Security Administration (NNSA) nuclear facilities located in areas prone to seismic activity. The results presented herein could aid in the improvement of DOE-STD-1020, the DOE Standard that addresses seismic risk analysis and capacity evaluation in DOE facilities. DOE-STD-1020 refers to the requirements in American Society of Civil Engineers (ASCE) 4-98, now superseded by ASCE 4-16, that shall be met in performing dynamic response analyses and generating in-structure response spectra, provided that such requirements are consistent with the requirements of ASCE/Structural Engineering Institute (SEI) 43-05. Moreover, the results presented herein could also aid in the updating of section C3.1.1. of ASCE 4-16 to account for the effects of aging on the stiffness of reinforced elements and American Concrete Institute (ACI) 349.3R-18, “Report on Evaluation and Repair of Existing Nuclear Safety-Related Concrete Structures.” Ultimately, this work can assist the risk assessment of potential lifetime extension of the existing US commercial nuclear fleet (light water reactors) and the safety analysis of the emerging advanced nuclear reactors. The proposed proof-of-concept methodology employs open-source DOE computational tools and is transferable to commercial software commonly used by engineering firms.

42 ENGINEERING↗

DOE OSTI2024

Materials for the Photoluminescence-Based Detection of Economically Critical Metals

Critical metals, such as rare earth elements (REEs), cobalt, lithium, aluminum, nickel, and others, are essential to advanced technologies and renewable energy in particular. Widespread global adoption of renewable energy technologies has spurred dramatic demand increases for these metals; however, the global supply of these metals is highly monopolistic and conventional mining poses economic and environmental challenges. As a result, there is increasing interest in domestic production from alternative resources such as coal and its utilization byproducts. Slow and expensive characterization costs remain a significant barrier for domestic production. Here, luminescent sensing materials and platforms are presented that provide an alternative to the current state-of-the-art characterization methods; highly sensitive and selective sensing materials for cobalt, aluminum, and rare earth elements are presented, as well as compact, inexpensive platforms capable of analyzing signal from these materials for rapid characterization of critical metal content.

Crawford, Scott↗

DOE OSTI2024

Materials for the Photoluminescence-Based Detection of Economically Critical Metals

Crawford, Scott↗

DOE OSTI2024

Development of Leaching Processes for the Recovery of Rare Earth Elements from Acid Mine Drainage Precipitates

Acid mine drainage (AMD) has been a challenge for mine operators to address and has had significant environmental impacts when there is a failure to address it. Fortunately, there is a regulation in the US that requires the treatment of AMD before water can be discharged into the environment. AMD is generated when sulfide minerals are exposed to water and air from mining. The acidic water then leaches metals from the surrounding rock, creating the potential for environmental contamination of this acidic water containing dissolved metals. AMD can contain high concentrations of metals like iron, aluminum, and manganese and also have been shown to contain trace concentrations of critical minerals, including rare earth elements (REEs). This environmental waste stream is now being researched as a potential source for REEs. There is a patented process for processing and extracting REEs from AMD which produces rare earth oxide preconcentrate (REOP) from AMD treatment precipitates and a final stage mixed rare earth oxide (MREO) product. This body of research examines a selective leaching process for each of these products and determines the activation energy associated with the leaching processes. Acid leaching with HCl was examined to selectively leach REEs from REOP while contaminant metals remained in the solid residue. The maximum leaching recovery of the REEs from the REOP was approximately 90% and an activation energy of 6.4 kJ/mol at pH 3.0. Ammonium chloride leaching was examined to selectively remove contaminant metals from a MREO product. The ammonium chloride process successfully leached major contaminant metals in excess of 85% recovery and had a maximum activation energy of 40.0 kJ/mol.

01 COAL, LIGNITE, AND PEAT↗

DOE OSTI2026

MINLP for regularized symbolic regression with applications to data-driven modeling of critical minerals processes

The poster summarizes recent advances in symbolic regression developed as part of the PrOMMiS project over the past year. In particular, it describes the comparison of surrogates for critical minerals (CM) & rare earth element (REE) recovery flowsheets obtained via symbolic regression and ALAMO. It also compares the predictive ability and solvability of optimization models that incorporate these surrogates.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Low-cost, portable optical sensors for critical mineral prospecting and process monitoring

A combination of projected demand increases for economically critical minerals and a monopolistic global marketplace for these minerals has caused concern over supply chain vulnerabilities, which would impact energy, national defense, and advanced technology production. Domestic production of critical minerals is hindered by expensive and non-portable methods for analyzing metal concentration, which is vital both for resource prospecting and process monitoring. Here, a suite of luminescent materials along with portable instrumentation is presented for fluorescence-based detection of trace concentrations of critical minerals (cobalt, rare earth elements, and aluminum) as well as common gangue metals that are removed during processing (iron and aluminum). A metal-organic framework comprised of zinc, adenine, and trimesic acid immobilized on a fiber optic tip is capable of sensing part-per-billion concentrations of terbium, europium, dysprosium, and samarium through a sensitization approach, in which individual elements produce characteristic emission bands enabling multiple rare earths to be simultaneously detected and distinguished. A deep-UV light emitting diode is used as the excitation source, while a portable spectrometer is used to detect the emitted light. A similar optical set-up is coupled with two different carbon dot materials, which can detect low part-per-million concentrations of cobalt and iron in acidic environments. Metal-organic framework thin films comprised of copper and 2-aminoterephthalic acid are used in tandem with a portable optical set-up to further detect aluminum, with successful deployment in real fly ash leachates. Taken together, these technologies provide an inexpensive and sensitive path towards characterizing economically critical metals.

characterization and extraction of rare earth elem↗