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At least 361 records · Page 20

Affordable Development and Optimization of CERMET Fuels for NTP Ground Testing

CERMET fuel materials for Nuclear Thermal Propulsion (NTP) are currently being developed at NASA's Marshall Space Flight Center. The work is part of NASA's Advanced Space Exploration Systems Nuclear Cryogenic Propulsion Stage (NCPS) Project. The goal of the FY12-14 project is to address critical NTP technology challenges and programmatic issues to establish confidence in the affordability and viability of an NTP system. A key enabling technology for an NCPS system is the fabrication of a stable high temperature nuclear fuel form. Although much of the technology was demonstrated during previous programs, there are currently no qualified fuel materials or processes. The work at MSFC is focused on developing critical materials and process technologies for manufacturing robust, full-scale CERMET fuels. Prototypical samples are being fabricated and tested in flowing hot hydrogen to understand processing and performance relationships. As part of this initial demonstration task, a final full scale element test will be performed to validate robust designs. The next phase of the project will focus on continued development and optimization of the fuel materials to enable future ground testing. The purpose of this paper is to provide a detailed overview of the CERMET fuel materials development plan. The overall CERMET fuel development path is shown in Figure 2. The activities begin prior to ATP for a ground reactor or engine system test and include materials and process optimization, hot hydrogen screening, material property testing, and irradiation testing. The goal of the development is to increase the maturity of the fuel form and reduce risk. One of the main accomplishmens of the current AES FY12-14 project was to develop dedicated laboratories at MSFC for the fabrication and testing of full length fuel elements. This capability will enable affordable, near term development and optimization of the CERMET fuels for future ground testing. Figure 2 provides a timeline of the development and optimization tasks for the AES FY15-17 follow on program.

Hickman, Robert R.↗

Phase Equilibria and Thermochemistry of Advanced Fuels: Modeling Burnup Behavior (Final Report)

Achieving the goal of developing advanced fuel concepts that meet the DOE objectives of being robust, demonstrating high performance, and are more tolerant of accident conditions than current fuel systems will require a thorough understanding of the thermophysical and thermochemical properties of the constituent materials. Non-oxide fuel systems are being explored under the Advanced Fuels Program that hold significant promise for improved performance and accident tolerance, including the uranium silicide-based system considered in the current work. Prospective cladding materials currently considered that contribute to improved accident tolerance include silicon carbide composites and ferritic alloys (Fe-Cr-Al base compositions). Thus, the effort developed thermochemical models and values, supported with targeted experiments, to evaluate the ferritic alloy and silicon carbide composite cladding systems in contrast to current zirconium alloy cladding. The developed detailed understanding will serve to aid in relatively early screening of candidate systems to avoid wasted effort, guide development of new fuel forms, and to provide a basis for predicting and modeling fuel performance. Major deliverables for the project included: Thermochemical assessment and models of phases in the U-Si and U-Si-N systems; thermochemical evaluation supported by experimental measurements of fuel-cladding interactions of silicide fuel with baseline zirconium, ceramic composite, and ferritic alloy cladding; thermochemical assessment and models of phases supported by experimental measurements for silicide fuel with key fission products provided in a dataset and reported in refereed publications. Within the project a significantly refined U-Si phase diagram was developed and reported that now includes homogeneity ranges for key phases, such at the U 3 Si 2 proposed fuel phase, and settles issues with regard to uncertainty in the stability of some phases. Computational efforts together with key experiments has determined phase formation in interactions between U 3 Si 2 and Zircaloy-4 cladding material, a ferritic FeCrAlY alloy of interest as an advanced cladding material, and silicon carbide, also of interest as a fiber-reinforced composite cladding. As expected, very significant reactions occur between U3Si2 and Zircaloy-4, with much less interaction at higher temperatures for the ferritic alloy, and finally interactions with SiC only in the region of contact. A potentially major issue is the stability of U 3 Si 2 fuel that has undergone significant burnup. The result is the loss of the uranium metal, liberating silicon, and the formation of concomitant fission product elements that either dissolve in the U 3 Si 2 phase or form independent, and possibly silicide phases. A combination of experimental determinations of phase formation of U 3 Si 2 reacted with representative fission products yttrium, gadolinium, cerium, zirconium, and molybdenum and first principles calculations has helped understand the fuel chemistry. The behavior of the U 3 Si 2 phase and the partitioning of silicon to possible fission product phases with burnup was thus determined, with significant dissolution in U 3 Si 2 of cerium, gadolinium, zirconium, and plutonium predicted along with independent phase formation of a U-Mo-Si ternary phase, yttrium silicide, and elemental selenium. It can be concluded that at significant burnup there will be a very minor amount of the U 3 Si 2 fuel phase that will decompose to a lower silicide or a uranium alloy as silicon preferentially forms a secondary phase.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Unitized Regenerative Fuel Cell System Gas Storage/Radiator Development

The ancillary components for Unitized Regenerative Fuel Cell (URFC) Energy Storage System are being developed at the NASA Glenn Research Center. This URFC system is unique in that it uses the surface area of the hydrogen and oxygen storage tanks as radiating heat surfaces for overall thermal control of the system. The waste heat generated by the URFC stack during charging and discharging is transferred from the cell stack to the surface of each tank by loop heat pipes. The heat pipes are coiled around each tank and covered with a thin layer of thermally conductive layer of carbon composite. The thin layer of carbon composite acts as a fin structure that spreads the heat away from the heat pipe and across the entire tank surface. Two different sized commercial grade composite tanks were constructed with integral heat pipes and tested in a thermal vacuum chamber to examine the feasibility of using the storage tanks as system radiators. The storage radiators were subjected to different steady-state heat loads and varying heat load profiles. The surface emissivity and specific heat capacity of each tank were calculated. The results were incorporated into a model that simulates the performance of similar radiators using lightweight, space rated carbon composite tanks.

Jakupca, Ian↗

Proton Exchange Membrane (PEM) Fuel Cells for Space Applications

This presentation will provide a summary of the PEM fuel cell development at the National Aeronautics and Space Administration, Johnson Space Center (NASA, JSC) in support of future space applications. Fuel cells have been used for space power generation due to their high energy storage density for multi-day missions. The Shuttle currently utilizes the alkaline fuel cell technology, which has highly safe and reliable performance. However, the alkaline technology has a limited life due to the corrosion inherent to the alkaline technology. PEM fuel cells are under development by industry for transportation, residential and commercial stationary power applications. NASA is trying to incorporate some of this stack technology development in the PEM fuel cells for space. NASA has some unique design and performance parameters which make developing a PEM fuel cell system more challenging. Space fuel cell applications utilize oxygen, rather than air, which yields better performance but increases the hazard level. To reduce the quantity of reactants that need to be flown in space, NASA also utilizes water separation and reactant recirculation. Due to the hazards of utilizing active components for recirculation and water separation, NASA is trying to develop passive recirculation and water separation methods. However, the ability to develop recirculation components and water separators that are gravity-independent and successfully operate over the full range of power levels is one of the greatest challenges to developing a safe and reliable PEM fuel cell system. PEM stack, accessory component, and system tests that have been performed for space power applications will be discussed.

Bradley, Karla↗

Hydrogen-bromine fuel cell advance component development

Advanced cell component development is performed by NASA Lewis to achieve improved performance and longer life for the hydrogen-bromine fuel cells system. The state-of-the-art hydrogen-bromine system utilizes the solid polymer electrolyte (SPE) technology, similar to the SPE technology developed for the hydrogen-oxygen fuel cell system. These studies are directed at exploring the potential for this system by assessing and evaluating various types of materials for cell parts and electrode materials for Bromine-hydrogen bromine environment and fabricating experimental membrane/electrode-catalysts by chemical deposition.

Charleston, Joann↗

FY2022 Progress Report for Advanced Re-fabrication/Re-instrumentation Capability Development

In support of performing follow-on irradiation experiments with previously irradiated materials, the Halden Reactor Project developed unique and state of the art capabilities to refabricate and re-instrument previously irradiated materials. Such materials were used in in-pile tests at the Halden reactor, and out-of-pile tests for example using furnaces as a heat source. The decision to close the Halden Reactor Project results in the loss of this refabrication and re-instrumentation capability. As a result, the United States (U.S.) Department of Energy (DOE) has determined to develop refabrication and re-instrumentation capability at the unique shielded facilities at Idaho National Laboratory (INL). The development of refabrication capability has been completed and demonstrated. This report focuses on the complementary aspects of reinstrumentation and the progress to-date. Halden spent nearly 30 years developing both refabrication and re-instrumentation. Collaboration with Halden is allowing Idaho National Laboratory (INL) to develop this capability much more rapidly. In FY-21 the results include development of the capability to drill annular center holes in ceramic UO2 fuel pellets, development of fuel rod end caps with feedthroughs for centerline instrumentation inside the rodlet, The procurement of both fuel drilling and welding demonstration equipment from Halden, evaluation of surface thermocouple attachments to support better understanding of temperature measurement uncertainties, and finally, the conceptual design of a new shielded enclosure where advanced refabrication and re-instrumentation equipment can be housed. In FY-22, the results include; Completing set up of the drilling and welding modules procured from Halden, and early experimental trials using that equipment.; Completing set up of an out-of-cell circumferential weld system to allow for further weld development to take place and support fabrication of fuel for fresh fuel experiments.; Evaluation of the Hot Fuel Examination Facility (HFEF) infrastructure to support future installation of advanced re-fabrication/re-instrumentation equipment, specifically related to necessary infrastructure for cryo-drilling.; Developments in dry-drilling alternative. Including experimental studies showing cordierite is the most suitable surrogate for UO 2 for performing drilling studies. That drilling performance is enhanced when a fuel-clad bonding condition is simulated.; Conceptual design completed for attaching surface thermocouples to irradiated fuel in support of TWIST capsule experiments. The authors would like to thank the numerous colleagues at INL and Halden who provided support in accomplishing this work. Their support both material and intellectual is invaluable in advancing the state of the art and establishing the capabilities for refabrication and re-instrumentation at INL.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

FCET Solid Oxide Fuel Cell Testing and Development (CRADA 526) (Final Report)

Pacific Northwest National Laboratory (PNNL) tested electrolyte coatings from Fuel Cell Enabling Technologies, Inc. (FCET) for use in solid oxide fuel cells (SOFCs). The key technology held by FCET is a process to deposit thin layers of oxide materials, less than 1 μm in thickness. The range of possible materials that can be deposited with their method is broad, but this project focused on the gadolinium-doped ceria (GDC) and yttria-stabilized zirconia (YSZ) electrolytes for SOFCs. Thin, gas tight electrolyte membranes have been a long-sought target in SOFC research. The thinner the electrolyte, the lower the cell resistance, and the higher performance of the cell (or the lower the operating temperature). A YSZ thickness of 1 μm would be a step change from the state-of-the-art, tape-cast electrolytes (~10 μm). An in-house prototype SOFC stack from FCET was first tested. The sealing geometry of the prototype stack was determined to be problematic, and testing shifted to button cells. Anode-supported solid oxide electrolysis cell (SOEC) button cells without an electrolyte layer were produced at PNNL and sent to FCET for coating with electrolyte. Three cells were tested with a gadolinium-doped ceria (GDC) electrolyte applied via spin coating. GDC was chosen for its conductivity at lower temperatures than YSZ. All three cells failed during initial reduction under hydrogen at 600°C. Testing then shifted to YSZ, which is the standard SOFC electrolyte. Several button cells were coated with YSZ and examined with scanning electron microscopy (SEM). A promising coating of ~1 mm thickness was observed under SEM. A similarly coated button cell was tested and failed similarly to previous tests during reduction at 600°C. The YSZ coating appeared dense and uniform in SEM analysis. The roughness of the underlying Ni/YSZ anode is on the order of 1 μm, and that may have compromised the gas-tightness of the coating. Further development is warranted to understand and refine the coating process. Thin YSZ applied via this spin-coating technique could be used as a low-cost, drop-in replacement in large-scale SOFC manufacturing processes, improving cell performance and lowering the cost per watt of SOFCs.

30 DIRECT ENERGY CONVERSION↗

UO 2 -liquid metal suspension fuel concept for enhanced passive safety of LWRs: A heat pipe case study

This work proposes a novel fuel concept for use in light-water type reactors (LWRs): UO 2 particles suspended in a low-melting-point liquid metal (LM). This new fuel form offers lower energy density and higher thermal conductivity, thus enhancing the fuel’s thermal performance compared to sintered UO 2 pellets. Two candidate alloys for the LM are proposed based on previous studies into accident-tolerant fuels: Bi-Pb-Sn and Pb-Sn. Ten research questions are provided to guide future development of this fuel. A simple heat pipe model was constructed by coupling a reactor physics code to a heat transport code and other physics modules. Scoping calculations were performed on this model core as a preliminary investigation into five of the research questions. A fuel with 13 wt% UO 2 was shown to maintain a steady-state peak coolant channel wall temperature below 400 °C, and maintain criticality via self-regulating reactivity feedback. Shortcomings of the present model are discussed in this work, along with proposed future model improvements and fuel development. The appendix provides an example of a reactor concept that could be developed to utilize this fuel, but more modeling and experimental work are needed before a full reactor concept can be developed.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Heavy-Duty Hydrogen Fueling Station Corridors

Developing zero-emissions fueling corridors requires assessment of technologies that may be utilized in the M/HDV sector. BEVs and FCEVs are leading choices of zero emissions technology and work is required to understand how infrastructure may be deployed and at what cost to facilitate M/HDV decarbonization goals.

class 6↗

Iodine Mass Tracking Research and Development Needs for Pyrochemical Fuel Cycles

This report was generated jointly by Argonne National Laboratory (ANL) and Idaho National Laboratory to provide a high-level summary of the current knowledge on the behavior of fission product iodine during reprocessing of used nuclear fuel, as well as provide recommended path forward for research and development activities to fill particular knowledge gaps. The focus of this work is on pyrochemical processing as is applied to light water reactor (LWR) oxide-based used nuclear fuels (UNF), however, some discussion of electrorefiner behavior from metal fuel processing equipment is also included.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Hybrid Solid Oxide Fuel Cell/Gas Turbine Model Development for Electric Aviation

A thermodynamic model was developed and validated to analyze a high-performance solid oxide fuel cell and gas turbine (SOFC-GT) hybrid power system for electric aviation. This study used a process simulation software package (ProMax) to study the role of SOFC design and operation on the feasibility and performance of the hybrid system. Standard modules, including compressor, turbine, heat exchanger, reforming reactor, and combustor were used from the ProMax tool suite while a custom module was created to simulate the SOFC stack. The model used an SOFC test data set as an input. Additional SOFC stack performance effects, such as pressure, temperature, and utilization of air and fuel, were added from open source data. System performance predictors were SOFC specific power, fuel-to-electricity conversion efficiency, and hybrid system efficiency. Using these input data and predictors, a static thermodynamic performance model was created that can be modified for different system configurations and operating conditions. Prior to creating the final aircraft performance model, initial demonstration models were developed to validate output results. We used the NASA SOFC model as a benchmark, which was created with their Numerical Propulsion System Simulator (NPSS) software framework. Our output results matched within 1% of both the NASA model and open source SOFC performance data. With confidence gained in the accuracy of this model, a 1-MW SOFC-GT hybrid power system was constructed for an aircraft propulsion concept. Overall hybrid system efficiencies of > 75% FTE were observed during standard 36,000 feet cruise flight conditions.

30 DIRECT ENERGY CONVERSION↗

Unitized Regenerative Fuel Cell System Dryer-Humidifier Analytical Model Development

A Unitized Regenerative Fuel Cell (URFC) Energy Storage System is being developed at the NASA Glenn Research Center. This URFC system is unique in that it uses regenerative gas dryers/humidifiers that are mounted on the surface of the gas storage tanks that act as the radiators for thermal control of the URFC system. As the gas storage tanks cool down during URFC charging the regenerative gas dryers/humidifiers dry the hydrogen and oxygen gases produced by electrolysis. As the gas storage tanks heat up during URFC discharging, the regenerative gas dryers/humidifiers humidify the hydrogen and oxygen gases used by fuel cell. An analytical model was developed to simulate the URFC system's regenerative gas dryers/humidifiers. The model is in the form of an EXCEL@ worksheet that allows the investigation of the regenerative gas dryers/humidifier performance as a function of time and position within the regenerative gas dryers/humidifiers, as well as other key system variables. Finite Element Analysis (FEA) modeling of the regenerative gas dryers/humidifier and gas storage tank wall was also done to analyze spatial temperature distribution within the regenerative gas dryers/humidifiers and the localized tank wall. Test results obtained from the testing of the regenerative gas dryers/humidifiers in a thermal vacuum environment were used to corroborate the analyses.

Burke, Kenneth A.↗

Handling and Properties of Methanol as a Marine Fuel

Given the increasing concern around greenhouse gas emissions and the decline in the availability of fossil fuels, there is increasing global demand to develop alternate fuels for maritime transportation that are sustainable and which have lower greenhouse gas emissions. Methanol is one such alternative fuel that has garnered considerable attention given its potential to be produced by more sustainable processes and its more favorable greenhouse gas emission profile in comparison with current fossil fuels. Understanding the physical and chemical properties of methanol under a range of conditions is essential for its development as a marine fuel. In this study, we seek to define physical and chemical properties of different methanol samples to simulate real-world storage conditions as these data are lacking in the literature. Several methanol samples were evaluated: nearly pure methanol; International Organization for Standardization (ISO) marine methanol (MM) grades A, B, and C; and methanol plus higher alcohols. We first evaluated all methanol samples for impurities, acetic acid content, density, and distillation range. We then characterized the effects of water absorption and found that methanol can easily absorb unacceptable water content from humid air within hours, necessitating storage conditions that prevent this process. In eight-week aging experiments at 20 °C and 40 °C in ambient air, we did not observe significant oxidation for any of the methanol samples; however, we did observe increases in acid number. We assessed the impact of contamination of methanol with water, marine gas oil (MGO), and an MGO–biodiesel mixture on density, viscosity, distillation range, and lubricity. Finally, we show that MGO contamination of methanol results in a slight increase in sooting tendency. In aggregate, our results provide an in-depth analysis of physical and chemical properties of methanol as well as the impacts of storage conditions and impurities on the properties of fuel methanol.

09 BIOMASS FUELS↗

A Design and Fabrication Options Trade Study for Metallic Fuel without Internal Sodium Bonding

Nuclear fuels using alloys of uranium, or metallic fuels, have many beneficial properties. The classical metallic fuel design uses a loose fitting cylindrical “slug” of fuel placed inside stainless-steel cladding tubes where the gap is filled with sodium. This sodium bond is liquid at operating temperature and conducts heat from the slug to the cladding, especially in early life before fuel swells into contact with the cladding. Despite the benefits of sodium bonding, there is a desire to develop metallic fuel technologies without it chiefly to reduce chemical reaction hazards in spent fuel storage from sodium fast reactors operating on once-through fuel cycles. Elimination of the sodium bond may also help unlock potential benefits for fuel fabrication, reactor neutronics, and compatibility with other types of reactors. Creating a sodium-free metallic fuel revolves around the problem of manufacturing fuel slug geometries which are in close contact with the cladding at beginning of life to facilitate heat transport while alleviating fuel-cladding chemical interactions (FCCI) at this interface and providing enough free volume to accommodate fuel swelling. Accelerating development and qualification of this fuel system will require careful selection of design and manufacturing options. To this end, a design trade-off study was performed to evaluate candidate options. Several design and manufacturing options were assessed, weighted, scored, and ranked with respect to fabrication, normal reactor operation, off-normal scenarios, and back-end considerations. This effort was performed both for “baseline” needs, which represented a once-through fuel cycle at temperatures and burnups known to be viable for sodium-bonded metallic fuel, and for “enhanced” needs to represent opportunities for closed fuel cycles and/or more aggressive temperatures/burnups. The outcomes of this study prioritized a baseline technology using U-Zr alloy with additives to mitigate FCCI, produced in annular slug geometry by continuous casting, clad in austenitic stainless-steel alloy, and followed by a final step to swage the cladding down to close the gap. This study prioritized an enhanced fuel technology using U-Mo alloy, also produced by continuous casting into an annular geometry, followed by coating/plating with an FCCI barrier on the slug, again with a final step to swage the cladding diameter down using oxide dispersion strengthened steel. It was noted that development of the enhanced fuel technology would entail more risk, thus U-Zr alloy was put forth as a backup to U-Mo if challenges are encountered with FCCI barriers, and advanced ferritic/martensitic steels are put forth as a backup to oxide dispersion strengthened steels if swaging and welding are found unworkable.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Development of dispensing hardware for safe fueling of heavy duty vehicles

The development of safe dispensing equipment for the fueling of heavy duty (HD) vehicles is critical to the expansion of this newly and quickly expanding market. This paper discusses the development of a HD dispenser and nozzles assembly (nozzle, hose, breakaway) for these new, larger vehicles where flow rates are more than double compared to light duty (LD) vehicles. This equipment must operate at nominal pressures of 700 bar, -40o C gas temperature, and average flow rate of 5-10 kg/min at a high throughput commercial hydrogen fueling station without leaking hydrogen. The project surveyed HD vehicle manufacturers, station developers, and component suppliers to determine the basic specifications of the dispensing equipment and nozzle assembly. The team also examined existing codes and standards to determine necessary changes to accommodate HD components. From this information, the team developed a set of specifications which will be used to design the dispensing equipment. In order to meet these goals, the team performed computational fluid dynamic, pressure modelling, and temperature analysis in order to determine the necessary parameters to meet existing safety standards modified for HD fueling. The team also considered user, operational, and maintenance requirements, such as freeze lock which has been an issue which prevents the removal of the nozzle from LD vehicles. The team also performed a failure mode and effects analysis (FMEA) to identify the possible failures in the design. The dispenser and nozzle assembly will be tested separately, and then installed on an innovative, HD fueling station which will use a HD vehicle simulator to test the entire system.

08 HYDROGEN↗

The Three-D Flow Structures of Gas and Liquid Generated by a Spreading Flame Over Liquid Fuel

We developed a new experimental technique called: Combined laser sheet particle tracking (LSPT) and laser holographic interferometry (HI), which is capable of measuring the transient behavior of three dimensional structures of temperature and flow both in liquid and gas phases. We applied this technique to a pulsating flame spread over n-butanol. We found a twin vortex flow both on the liquid surface and deep in the liquid a few mm below the surface and a twin vortex flow in the gas phase. The first twin vortex flow at the liquid surface was observed previously by NASA Lewis researchers, while the last two observations are new. These observations revealed that the convective flow structure ahead of the flame leading edge is three dimensional in nature and the pulsating spread is controlled by the convective flow of both liquid and gas.

Tashtoush, G.↗

Unitized Regenerative Fuel Cell System Gas Dryer/Humidifier Analytical Model Development

A lightweight Unitized Regenerative Fuel Cell (URFC) Energy Storage System concept is being developed at the NASA Glenn Research Center (GRC). This Unitized Regenerative Fuel Cell System (URFCS) is unique in that it uses Regenerative Gas Dryers/Humidifiers (RGD/H) that are mounted on the surface of the gas storage tanks that act as the radiators for thermal control of the Unitized Regenerative Fuel Cell System (URFCS). As the gas storage tanks cool down during URFCS charging the RGD/H dry the hydrogen and oxygen gases produced by electrolysis. As the gas storage tanks heat up during URFCS discharging, the RGD/H humidify the hydrogen and oxygen gases used by the fuel cell. An analytical model was developed to simulate the URFCS RGD/H. The model is in the form of a Microsoft (registered trademark of Microsoft Corporation) Excel worksheet that allows the investigation of the RGD/H performance. Finite Element Analysis (FEA) modeling of the RGD/H and the gas storage tank wall was also done to analyze spatial temperature distribution within the RGD/H and the localized tank wall. Test results obtained from the testing of the RGD/H in a thermal vacuum environment were used to corroborate the analyses.

Burke, Kenneth A.↗

Interdisciplinary studies on the development of nuclear-fueled circulatory support systems: Collaboration of industry and academe

The purpose of this report is to acquaint the Houston community with specific areas of available technology, both public and private, to demonstrate to industry how this technology may be acquired and put to use to provide new and useful services for man. Much of the technology utilized in the development of nuclear-fueled circulatory support systems in our laboratories has evolved from industry, NASA, and AEC; our projects involve radiation biology, thermodynamics, energy transfers, hemodynamics, hematology, pathology, and surgery.

Norman, J. C.↗