Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “construction technology”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 361 records · Page 20
All sourcesNASA NTRSDOE OSTI
DOE OSTI2022

Thermal-Mechanical Analysis of an Additive Manufacturing Ceramic Heat Exchanger for High-Temperature Recuperator in a sCO2 Power System

Supercritical CO2 (sCO2) Brayton power cycle can be configured in a closed-loop power system and has a potentially high cycle efficiency. Compactness and high efficiency of a sCO2 power block make the sCO2 Brayton cycle a versatile power cycle in broad applications. While many heat sources are of sufficient intensity to produce high temperature working fluids to achieve high cycle efficiency, the thermal-mechanical stability of traditional materials (e.g., steels and nickel-based superalloys) used in construction of heat exchangers and turbine components limits the operating conditions and thus thermodynamic efficiency of the system. This effort seeks to establish the viability of ceramic heat exchanger technologies for the most extreme operating conditions envisioned for power generation and other high temperature processes. Heat exchangers constructed from ultra-high temperature ceramics, a class of extreme environment materials featuring melting points (Tmp.) above 3000 degrees C, is particularly appealing for sCO2 Brayton cycles given their ultra-low creep rates and very high retained strength at low homologous temperatures (i.e., T < 0.5 Tmp., or at least 1500 degrees C). To translate these materials properties to ultra-high temperature heat exchangers, innovations are required in ceramic manufacturing techniques to realize the complex architectures featured in compact heat exchangers with high power density. With appropriate processing, ZrB2-SiC based compositions can be sintered to near full density and shaped into complex topologies via ceramic additive manufacturing methods. This paper analyzes heat exchanger designs and explores thermal-mechanical implications of the operating environment. Thermal flow, heat transfer, and conjugate mechanical analyses provide insights into benefits and risks associated with the design approach.

additive manufacturing↗
DOE OSTI2025

Benefits Of Automated Construction And Energy Efficiency Measures In Modular Homes

This article builds on and adds to a Buildings XV publication that introduced the Transformative Efficiency and Automation in Modular Homes (TEAMH) project. The TEAMH project sought to develop a scalable solution for producing modular homes with 20-50% energy savings and similar cost relative to site-fabricated single-family home construction. A key aspect of the project was assessing the potential for labor cost reductions through automation-assisted construction using light gauge steel (LGS). To quantify the advantages of this approach, side-by-side comparisons were made between traditional wood-framed construction and automation-assisted LGS construction. This demonstration involved constructing one wood-framed wall and several LGS test walls, accompanied by a time-and-motion study. The results indicated that automation assistance could decrease construction time and associated labor costs by as much as 46%. High-performance envelope technologies for exterior insulation and air sealing were evaluated to compare modular homes with site-built homes that meet the International Energy Conservation Code (IECC). A key technology considered was vacuum insulation panels (VIPs) with fiberglass cores. Guarded hot box testing of multiple full-scale wall assemblies containing different combinations of exterior continuous insulation systems containing phenolic foam and VIPs. Testing on various full-scale wall assemblies revealed that, with LGS construction, cavity insulation had minimal impact on exterior wall performance. Omitting cavity insulation can reduce labor and material costs while streamlining manufacturing, as its installation is labor-intensive and not easily automated due to the need for precise placement around wiring and other internal components. Guarded hot box tests of multiple LGS test walls with foam and VIP-based exterior insulation systems achieved R-values of up to 31 hr-ft2-°F/Btu. Finally, building energy modeling of multiple modular home designs indicated that the upgraded envelope assemblies can yield heating energy savings of up to 50% and cooling energy savings of up to 30% compared to IECC 2018 standards.

Shrestha, Som [ORNL] (ORCID:0000000183993797)↗
DOE OSTI2025

Packages of Distributed Energy Technologies Demonstrating Demand Flexibility at Community Scale

The combination of increased electric load growth across all sectors, deferred electrical infrastructure investment, and other factors resulting in variable electric power supply, has created technical challenges to maintaining a resilient and reliable grid. Many federal, regional, and local efforts are in play to modernize the electric grid, including advancing building technologies and distributed energy resources (DERs) that are utilizing smarter controls to become responsive to both occupant and grid needs. This report reviews ten pilot projects demonstrating how groups of buildings combined with behind-the-meter (BTM) DERs such as electric vehicle (EV) charging, battery storage, flexible HVAC and domestic hot water systems, and photovoltaic systems can reliably and cost effectively provide grid services. Each of the ten pilot projects aim to deliver both energy efficiency and demand flexibility (DF) while supporting load growth. The ten demonstration teams are piloting flexible DER packages across diverse communities of residential and commercial buildings to address a variety of regional grid needs. The outcomes of these pilot projects will be used to inform future scaling through utility program development. This paper characterizes the ten teams, showcasing the decision-making process used by each group to develop their packages (Section 2), the grid services they plan to deliver (Section 3), the types of DER packages selected for deployment within building sectors (Section 4) and trends between building sector, DER types, and grid services In order to achieve community scale benefits, the pilot projects must utilize aggregated control mechanisms for coordinating buildings and DERs together. Several types of coordinated control architectures have evolved amongst the teams, influenced by use type, existing market conditions, and integration type. Three coordinated controls architectures have been characterized, highlighting their use cases, benefits, challenges, and tradeoffs in their design. These insights can aid utilities, control vendors, and developers in scaling community-level energy systems (Paul, 2024). Ultimately, the technology packages selected by the ten teams will be coordinated to provide power system services, also known as grid services. Insights from these demonstrations will be useful for grid operators, regulators, aggregators and other stakeholders as they look to deploy demand flexible resources as grid services in the future. The grid services that each team is targeting for demonstration are described in Section 3 and Section 4. Methods for evaluating the grid services have been described in the paper Metrics for Evaluating Grid Service Provision from Communities of Grid-interactive and Efficient Buildings and other DER (MacDonald, 2023). To identify technology packages for demonstration, Section 2 shows that project teams used a range of analysis approaches, including building energy modeling, AMI data analysis, cost-benefit frameworks, and utility pilot data. Some teams emphasized technical modeling to quantify grid impacts and demand reduction potential, while others prioritized economic evaluations, stakeholder input, or exploratory pilots to inform deployment decisions. This diversity reflects the need to tailor selection methods to project goals, available data, and organizational context. Section 5 discusses trends between the DER technologies deployed and the grid service provisions from each team. Residential buildings (multifamily and single family) lean towards technologies that enhance energy efficiency (e.g. weatherization upgrades, smart thermostats) and onsite power generation integration (e.g. solar PV). Commercial building demonstrations prioritize technologies that ensure operational reliability (e.g. battery storage) and centralized energy management systems and optimization solutions. Teams that are deploying controllable storage-based technologies are more likely to provide grid services that require a near real-time response. Teams incorporating load shifting technologies like smart thermostats with HEMs are likely to include energy markets participation and customer bill management offerings. Campus demonstrations are adopting diverse sets of DERs to emphasize renewable generation, paired with centralized control. This section also describes technologies that were considered during project planning but ultimately excluded from final deployment. These demonstrations reveal that effective DER package design should be tailored to building type, customer segment, and construction vintage. Multifamily buildings benefit from centralized HVAC upgrades and supervisory controls, while single-family homes are well-suited for individualized technologies like solar, storage, and smart home energy monitors. Commercial and campus settings prioritize EMIS integration and load optimization. New construction enables cost-effective integration of DER-ready infrastructure, whereas retrofits require deployments aligned with owner and tenant value streams. For utility program planners, early coordination with developers and building owners, paired with segmented and modular program offerings, can improve adoption, scalability, and grid impact.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2022

Climate Impact on CO2 Capture Efficiency and Levelized Cost of Liquid solvent-based DAC (Direct Air Capture) System

The transition towards net-zero emission poses economic, technical, and political challenges for the commercial-scale deployment of CO2 removal technologies by 2050. The opportunities for large-scale deployment will largely depend on the distinctive conditions found in the different locations of the world such as energy cost, carbon intensity of energy source, construction, transportation, and weather conditions. In this work, we focus on one of the promising negative emission technology, DAC (Direct Air Capture), and its response to different weather conditions. This work presents two potential operation scenarios: (i) natural gas standalone, (ii) grid electricity connected DAC plant. For the first time, we investigated the influence of temperature and RH (relative humidity) of the air on liquid-based DAC system and its response to carbon capture efficiency and levelized cost of carbon capture with operational sensitivity analysis. It is observed that the overall energy demand decreases from 11.1 to 8.3 GJ/ton-CO2 as the CO2 capture rate increases from 40 to 85%. We observed that a CO2 capture rate of 75% is only possible above 17°C even at 90% RH and this drops tremendously at lower temperatures. It is also observed that water evaporation in the air contactor is highest at dry and low RH as expected. The sensitivity analysis showed that weather conditions are insensitive to CO2 capture efficiency for the liquid-solvent based DAC plant for both scenarios. In addition, higher CO2 capture efficiency is achievable from lower upstream methane emissions and carbon intensity of grid electricity (for grid-connected scenario). Lastly, the levelized cost of natural gas standalone scenario varies from 239.7 to 408.8 $/t-CO2 is sensitive to temperature conditions more than relative humidity and compared to electricity grid-connected scenario, from 265.3 to 440.1 $/t-CO2.

An, Keju↗
DOE OSTI2022

Reducing the Overnight Capital Cost of Advanced Reactors Using Equipment-Level Seismic Protective Systems

Consideration of the effects of earthquake shaking on the design and construction of nuclear power plants adds substantially to the overnight capital cost, with anecdotal estimates as high as 35+%, attributed to additional construction materials, need for one-off and sub-optimal designs of equipment due to conflicting design choices, the high cost of seismic qualification of equipment, and regulatory review. Safety-critical equipment in large light water reactors is designed and qualified for seismic demands imposed by the supporting reactor building, optimal mechanical designs are not possible, and designs of a given piece of equipment may vary with height above grade. Similar negative impacts are expected for advanced reactors unless the seismic design paradigm is changed. The overarching goal of this transformational MEITNER project, which involved a multidisciplinary engineering team and designers of three fundamentally different advanced reactors, was to adapt proven seismic isolation and damping technologies to operationalize modular protective systems for safety-class equipment inside advanced reactor buildings. Such seismic protective systems would be tightly integrated into design development for reactor support systems and balance-of-plant construction. The adoption of the technology, which is widely used in non-nuclear sectors, would simplify plant design, enable the use of standardized equipment and buildings, optimized for operational performance, and reduce plant size and weight. The need for site-specific equipment would be eliminated, enabling identical equipment to be used across multiple plants sited across the US and economies of scale, and catalyzing new interest and investment. The equipment-based protective systems would allow siting of advanced reactors in regions of high seismic hazard.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2024

1. Physical Security Engineering by Design for Nuclear Facilities; 2. Nuclear Power Plant Site Security Management – A Security Strategy; 3. The UAE Women in Nuclear Energy Security

1. Security by design, or SeBD, is a comprehensive approach that integrates the physical protection system of a nuclear plant into every stage of its existence. This includes planning, designing, constructing, commissioning, and operating the facility, using a combination of analytical, physical, technological, and procedural measures. Essentially, SeBD involves intentionally applying and incorporating security into all aspects of design and operation throughout the entire lifecycle of a facility. By implementing this methodology throughout various phases such as program development, process implementation, staff training and procedures management in conjunction with plant equipment, facilities can be optimized to minimize security risks without compromising functional design requirements. This ultimately improves the overall security posture of the site and reduces the need for costly modifications or additional security resources post-design. 2. A site security strategy is a living document that is revised on a periodic or event-driven basis, ensuring that site security operations and corresponding procedures provide long-term, effective protection for the entire nuclear power plant (NPP) site. A site security strategy aims to mitigate threats across the entire NPP site via in-depth defense approaches and mutual support; therefore, if a layer is omitted or altered, then the effect across all layers must be re-evaluated. Therefore, the aim of the site security strategy is to provide an appropriate, scalable security regime that deters, denies, delays, and detects incidents and, equally importantly, reassures legitimate users and the regulator that due diligence and regulatory compliance have been achieved, ensuring that the site is safe and secure. Robust access control for vehicles and pedestrians is at the heart of the strategy. Vehicle and pedestrian searching and screening are seen as the strongest mitigation methods against vehicle- and pedestrian-borne attacks. The security strategy must also be supported through comprehensive staff training and the development of robust processes, procedures, and planning. If all these measures are to be effective, then training must be implemented during each phase of construction, partial operation/commissioning, and full operation. No single element of site security is completely isolated from the influence of other elements. Ideally, consideration of all key elements will result in a security strategy that is integrated and proportional to the threat and that does not over specify individual security solutions through the application of isolated measures but rather applies a holistic, all-encompassing approach. 3. When women enter the labor force, numerous positive outcomes emerge, including increased GDP, educational gains, and decreased maternal mortality. Despite these benefits, women's employment rates and equality vary significantly worldwide as does support for women in the workforce. This paper will explore the multifaceted benefits of women's employment, the factors influencing labor force participation rates, and the urgency to achieve gender equality as outlined in the 2015 United Nations Sustainable Development Goals (SDGs). It will then examine the emerging presence of women in the traditionally male-dominated nuclear field, specifically within the United Arab Emirates (UAE) as a testament to their resilience and determination to break social norms and advance gender equality.

Zineddin, Dr. Z.↗
DOE OSTI2022

Closing the Gap: A Global Perspective [Slides]

Against the backdrop of negotiations at COP26, a group of internationally recognised research and technology organisations launched a collaboration, with the intention to identify the national and international technology-led opportunities to decarbonise fossil fuel basins globally. This study will evidence the opportunities available to players across the entire energy ecosystem. Governments and funders will be able to spread costs and investment risk, energy companies will develop a greater understanding of the global transition and possible opportunities to develop pilot projects worldwide, and there will be greater incentive to the supply chain once they are aware of the global applicability of certain technologies and technology solutions. Through the analysis and comparison of national energy systems, a number of Net Zero Deployment Strategies and Technology Priorities have been identified, that are shaping the direction of the construction of net zero integrated energy systems globally. These have been considered to design Recommendations for International Collaboration to accelerate the global energy transition.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2023

Development, Monitoring, and Control of Fracture Thermal Energy Storage in Crystalline Rock Formations (DEMO-FTES) [Abstract]

Approximately half of global energy consumption is used for heating and cooling. Because fossil fuels are used to meet most of this demand, heating and cooling of buildings produces a large portion of global greenhouse gas (GHG) emissions. The proposed project seeks to demonstrate the feasibility of a seasonal thermal energy storage concept called fracture thermal energy storage (FTES), which has the potential to dramatically lower energy requirements for heating and cooling and improve the resilience of building energy systems. FTES is a technique for building a highly efficient heat exchanger by creating a carefully designed set of fractures in the ground below a building. This heat exchanger allows thermal energy to be stored over seasonal timeframes—for example, hot thermal energy that is easily captured in the summer or energy from waste heat sources—to meet heating needs during colder months. FTES offers a solution with a relatively small footprint and lower cost compared to currently operating aquifer thermal energy storage (ATES) systems and could be used in the many areas without aquifers suitable for ATES. If commercialized, FTES systems could exceed the 2.5 TWh of energy storage per year from the more than 2,800 ATES systems in operation worldwide, which range from 0.1 MW to 30 MW. The savings in CO2 emissions per year are also expected to match or exceed individual ATES projects, with the largest, a 30 MW system used to provide heating and cooling to the University of Technology in Eindhoven in the Netherlands, estimated to save 13,000 tons of CO2 emissions per year. FTES utilizes mature drilling and fracturing technology and therefore has the potential to be rapidly commercialized once demonstrated. The ability to construct and establish flow through an FTES heat exchanger has been demonstrated by a previous project and the potential for efficient, large-capacity energy storage has been shown using numerical models. However, no experimental validation of these numerical estimates of thermal energy storage has been made. The first crucial need to advance FTES technology is to identify the sensitivity of key metrics such as thermal energy storage and production rates, capacities, and efficiencies to design parameters such as the number of fractures, depth/temperature of fractures, size of fractures, and circulation rates. The second crucial need is experimental testing of achievable thermal performance with optimized system design parameters. The proposed scope of work seeks to systematically address these two critical needs through a highly complementary international collaboration spanning theory, laboratory, and mesoscale field evaluation. The proposed work plan calls for using dimensional analysis and existing state-of-the-art numerical simulators to design carefully scaled laboratory and 10-meter-scale field tests of the thermal efficiency of FTES. The existing advanced laboratory and intermediate-scale field testbeds that will be used for this project will allow for detailed monitoring of the system performance during the test and of how the performance changes across time and length scales. These results will determine the feasibility of full- scale FTES systems. If the thermal performance is consistent with model predictions, the results will provide a strong economic justification for rapid commercialization of FTES technology in a wide range of geographical areas.

25 ENERGY STORAGE↗
DOE OSTI2020

Cryogenic goniometer for measurements in pulsed magnetic fields fabricated via additive manufacturing technique

Complex high-precision mechanical devices can be fabricated using 3-dimensional printing technology with the help of computer-aided design. Using 3D stereolithography, we have constructed a cryogenic goniometer for measurements in pulsed magnetic fields of up to 100 T, at temperatures as low as 0.5 K. We review the properties of several materials tested in developing the goniometer and report on its design and performance. The goniometer allows samples to be rotated in situ to a precision of 0.2 deg, so that the field can be applied at many different angles to the samples’ symmetry directions. Following its success, we establish that 3D printing is now a viable technology for pulsed-field and other cryogenic probes.

3D printing↗
DOE OSTI2024

A Review of Remote Welding and Nondestructive Examination Technologies for the DOE Standard Canister

The U.S. Department of Energy (DOE) manages a wide variety of spent nuclear fuel (SNF) that poses a unique management challenge. To help address this challenge, the DOE Standard Canister (DOESC), designed to remain sealed during handling, storage, transportation, and disposal, was conceptualized as a standardized containment vessel to accommodate DOE-managed SNF. Since 1999, several welding and examination processes have been independently developed for the DOESC’s closure welds. However, neither the DOESC nor these processes have been realized in an operational capacity. This review paper seeks to present and compare previously developed DOESC closure weld, nondestructive examination, and repair processes and technologies. Specific processes developed for the Idaho Spent Fuel Facility, in preparation for the Yucca Mountain geological repository, and the recent Road-Ready Demonstration Project are discussed. Further, specific focus is given to how different operating constraints and the American Society of Mechanical Engineers Boiler and Pressure Vessel Code (BPVC) have driven certain welding and nondestructive examination requirements. Historical DOESC welding and examination strategies are assessed against current regulatory and BPVC requirements. The comparison of welding processes, technologies, and DOESC designs presented in this review paper will inform further construction efforts for other commercial and DOE-managed SNF containments, including the DOESC.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2020

From Long-distance Entanglement to Building a Nationwide Quantum Internet: Report of the DOE Quantum Internet Blueprint Workshop

A Quantum Path Forward. Today, many scientific experts recognize that building and scaling quantum-protected and enhanced communication networks are among the most important technological frontiers of the 21st century. The international research community perceives the construction of a first prototype global quantum network-the Quantum Internet-to be within reach over the next decade. In February 2020, the U.S Department of Energy (DOE)'s Office of Advanced Scientific Computing Research hosted the Quantum Internet Blueprint workshop to define a potential roadmap toward building the first nationwide quantum Internet. The workshop participants included representatives from DOE national laboratories, universities, industry, and other U.S. agencies with serious interests in quantum networking. The goal was to provide an outline of the essential research needed, detail any engineering and design barriers, and suggest a path forward to move from today's limited local network experiments to a viable, secure quantum Internet.

97 MATHEMATICS AND COMPUTING↗
DOE OSTI2021

Opaque Envelopes: Pathway to Building Energy Efficiency and Demand Flexibility: Key to a Low-Carbon, Sustainable Future

The opaque envelope - the barrier that helps maintain comfortable indoor conditions regardless of prevailing outdoor conditions - is the single largest contributor to primary energy use in residential and commercial buildings. Residential and commercial buildings comprise 39% of total U.S. primary energy use [1]. The opaque envelope affects 25% of building energy use, or 10% of total U.S. primary energy use [2]. High-performance opaque envelope technologies, therefore, have substantial potential to reduce energy use in both new construction and existing buildings. Retrofits are particularly crucial to realizing the energy savings potential of the opaque envelope because nearly 85% of residential and 55% of commercial buildings that exist today will still exist in 2050 [1]. Building envelope performance is also important for occupant comfort, productivity, health, and well-being. Improving the energy performance of the opaque envelope in U.S. buildings is critical to achieving aggressive cli- mate goals that support a clean energy economy and an equitable energy future for all Americans. By reducing total building energy use and improving energy efficiency, envelope research and development (R&D) will have a significant impact on how low-carbon buildings can mitigate climate change.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2022

The Dual-Axis Radiographic Hydrodynamic Test Facility Capability Expansion (DCX) Strategy

The Dual-Axis Radiographic Hydrodynamic Test (DARHT) facility is a vital and important part of the Nation’s nuclear security enterprise. With more than two decades of operations, DARHT has a storied history. Conceived in the 1970s, constructed in the 1990s, and operational since 2000, DARHT has advanced from open-air hydrodynamic experiments (hydros) to foam-confined hydros, to vessel-confined hydros, and in 2022, the 75th hydro was successfully completed. Radiography has advanced from a single-axis, single-pulse system to a dual-axis, multi-pulse capability to variable fields of view (VFV) on both accelerators. The culmination of these experiences, accomplishments, and advancements has brought us to a very important question: What do the next two decades at DARHT look like? The world is not the same place it was in the 1990s when construction at DARHT was in progress. Evolving threats, an expanding mission, and technology changes necessitate adaptation. To adapt, the aging facility, accelerators, vessels, and detector systems require improvements to ensure DARHT remains the Nation’s hydrodynamic data foundation for stockpile certification, safety, surety, and global security threats.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
DOE OSTI2022

The Dual-Axis Radiographic Hydrodynamic Test Facility Capability eXpansion (DCX) Strategy

The Dual-Axis Radiographic Hydrodynamic Test (DARHT) facility is a vital and important part of the Nation’s nuclear security enterprise. The Department of Energy/National Nuclear Security Administration (DOE/ NNSA) Stockpile Stewardship Management Plan (SSMP) identifies DARHT as a weapons mission critical facility along with the need to modernize DARHT to support weapons modernization efforts. With more than two decades of operations, DARHT has a storied history. Conceived in the 1970s, constructed in the 1990s, and operational since 2000, DARHT has advanced from open-air hydrodynamic experiments (hydros) to foam-confined hydros, to vessel-confined hydros, and in 2022, the 75 th hydro was successfully completed. Radiography has advanced from a single-axis, single-pulse system to a dual-axis, multi-pulse capability to variable fields of view (VFV) on both accelerators. The culmination of these experiences, accomplishments, and advancements has brought us to a very important question: What do the next two decades at DARHT look like? The world is not the same place it was in the 1990s when construction at DARHT was in progress. Evolving threats, an expanding mission, and technology changes necessitate adaptation. The 2018 Nuclear Posture Review (NPR) states that the nuclear weapons infrastructure has suffered the effects of age and underfunding with no margin for further delay in recapitalizing the physical infrastructure. To adapt, the aging facility, accelerators, vessels, and detector systems require improvements to ensure DARHT remains the Nation’s hydrodynamic data foundation for stockpile certification, safety, surety, and global security threats.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
DOE OSTI2023

Tunable Laser-Plasma Amplifier (Final Report)

Exploration at the laser intensity frontier has always offered new avenues for physics and reaching beyond this frontier is a grand challenge. Present-day petawatt-class lasers provide focused intensities on target of 10 22 W/cm 2 , corresponding to electric fields of 200 TV/m, while laser-plasma amplification opens a route for focused intensities well above 10 23 W/cm 2 . Intensities in this range provide the ability to test quantum electrodynamics in the unexplored low-energy, strong-field regime where signatures for new physics may arise. The behavior of matter under such extraordinary conditions is a rich and fascinating subject, not only in its own right in fundamental plasma physics, but for the many potential applications that promise to enrich the natural sciences in the future, including compact electron-beam, ion-beam particle accelerators, and ultra-bright X-ray sources. Although laser systems are now under construction internationally to access intensities of 10 23 W/cm 2 , the current technologies used appear to be fundamentally limited to these intensities. The realization of intensities beyond 10 23 W/cm 2 using parametric amplification in plasmas promises a breakthrough in high-energy density physics. Parametric amplification using Raman scattering in a plasma could provide the enabling technology for the generation of ultra-high-power laser pulses, but a more complete understanding of the nonlinear optics of plasmas is required. There is a significant gap in well-diagnosed laser-plasma instability studies of nonlinear plasma-wave phenomena, which are critical to understand for future laser-plasma devices. To achieve an efficient laser-plasma amplifier, plasma waves must be driven to large amplitude where significant energy can be rapidly transferred from the pump to the seed over the pulse duration of the seed. Simulations suggest that this nonlinear pump depletion regime can be achieved in the “pi-pulse” amplification regime. While simulations show this optimal regime with efficient amplification, it has remained elusive in experiments and there is a growing consensus within the community that thermal effects and pump beam limitations prevent laser-plasma amplifiers from progressing through the linear regime into the nonlinear pump depletion regime. Previous experiments have been significantly limited by the laser power available at the necessary wavelengths for the seed laser; therefore, the amplification is required to start in the linear regime where it is sensitive to many deleterious effects. The enabling technology (currently unique to plasma-wave amplification in the world) at the University of Rochester is the ability to provide a seed pulse with sufficient power (4 mJ/100 fs seed) to immediately drive nonlinear plasma waves into the pi-pulse regime and to tune its wavelength to optimize the efficiency of energy transfer. This in combination with the state-of-the-art OMEGA heater beams providing multiple kilojoules in a nanosecond to sufficiently heat the plasma make this system distinct from previous studies. These heater beams will provide, for the first time in Raman amplification studies, a homogeneous electron temperature high enough to prevent pump beam propagation issues that have plagued previous experiments. These systems will provide a platform for driving electron-plasma waves into the nonlinear regime where pump depletion and pulse shortening are predicted to lead to high amplification efficiencies (>30%). The Team has made significant progress through prior support from DOE Fusion Energy Sciences [DOE Office of Science Award Number DE-SC0016253 (2016-2022)]. This includes twenty-two peer-reviewed manuscripts, one patent, ten contributed talks presented at international conferences, and research that was highlighted as invited talks at fifteen international conferences. The broader impacts of this research are evident in the support of early career scientists, two Ph.D. theses, four current graduate students, a Masters Project, two undergraduate researchers, and an underrepresented minority student hired through the California Alliance for Minority Participation who now works as a Research Engineer in the group. This research met all of the funded research objectives and the highlights from primary Raman amplification thrust of this work are discussed below and form the foundation for the proposed research.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2023

Front-End Engineering and Design: Project Tundra Carbon Capture System (Final Report)

As the next phase of Project Tundra, Minnkota Power Cooperative (MPC) completed a front-end engineering and design (FEED) study to install a post-combustion CO 2 capture system (CCS) at the MPC operated (Square Butte Electric Cooperative-owned) Milton R. Young Station (MRYS) Unit 2 (MRY2), a 477-MW power plant fueled by North Dakota lignite. The project team completed the FEED with Fluor’s Econamine FG Plus℠ (EFG+) technology and is taking the next steps leading up to start of construction. Team members included FEED technical lead Fluor Enterprises (Fluor); owner’s engineer and balance of plant (BOP) engineer Burns & McDonnell (BMcD); leading carbon capture consultants (David Greeson Consulting, Hunt International Energy Services); environmental consultants (AECOM, Agora Environmental), other BOP engineering consultants (Golder Associates, Nels); cost-share funding agency, the North Dakota Industrial Commission (NDIC); and the Energy & Environmental Research Center (EERC). Project Tundra’s goal is to implement carbon capture, utilization, and storage (CCUS) in North Dakota, while preserving the use of lignite. Future options could lead to revitalizing legacy oil fields and creating a new CO 2 enhanced oil recovery (EOR) industry. The topic of this report is the FEED study for the carbon dioxide capture portion of Project Tundra. Building on the findings of a pre-FEED study for MRY2, the key deliverables contained in this FEED study are: a) design, costing, and performance data needed to commence project financing activities; b) engineering and material balances required to file for all project permits; and c) a final project schedule. Based on the results of the previous pre-FEED study, MPC and its team evaluated two options to provide the large amount of steam needed to operate the CCS: 1) installation of new natural gas package boilers and a new pipeline to supply natural gas to the facility and 2) extraction of steam from the existing MRYS steam turbine generator. The FEED study was performed using the package boilers option, as it was deemed to have the lowest technical risk, overall cost, and cost uncertainty. A key feature of the design, however, was the mixing the natural gas boilers’ flue gas with the MRY2 flue gas. This increased the size of the CCS system. This design also enabled the tie-in of Unit 1 flue gas for times when Unit 2 is offline. The CCS was designed to capture a combined 12,978 short tons per day (STPD) of CO 2 from the flue gases produced by the existing MRY Unit 2 along with flue gas produced by the new boiler package within the CCS. The 12,978 STPD CO 2 capture is achieved by normally processing 100% of the total available MRY Unit 2 flue gas (considering full load operation) and 100% of the boiler package flue gas, then removing 90% of the CO 2 available from the processed flue gas streams.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2023

High-Temperature Sodium System Structural Health Monitoring (SHM) Technologies at the Mechanisms Engineering Test Loop (METL)

This report documents the deployment of non-destructive testing (NDT) technologies at the Mechanisms Engineering Test Loop (METL). METL became operational in September 2018 with the mission to provide an ecosystem for Advanced Reactor Development (ARD). METLs flagship facility’s primary purpose is conducting small to intermediate scale tests for Sodium Fast Reactors (SFR). Its resemblance to a commercial SFR’s intermediate heat transport system, prototypic operating conditions, and industrial construction practices/materials provides the overarching benefit of establishing a proving ground for devices of all technology readiness levels as well as commercial off-the-shelf equipment yet to be demonstrated on a sodium system.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

Non-destructive structural characterization of graphite components using mechanical resonance and deep learning

As compared to conventional nuclear reactors, microreactors have the potential to significantly reduce construction timelines and capital costs, decreasing the barriers for advanced nuclear reactor technologies. However, the lower power output of these microreactors (typically < 20 MWe) creates challenging economics if operation and maintenance costs cannot be sufficiently reduced. The compact size of these designs presents an opportunity for comprehensive in-situ structural health monitoring to provide real-time feedback in order to reduce operational costs associated with maintenance and downtime. Many microreactor concepts use graphite for both in-core neutron moderation and as a structural material, which has typically required some form of periodic and laborious inspection. This report provides a description and assessment of recent work with graphite to couple acoustic-based experimental measurements and characterization with machine learning models to mature structural health monitoring capabilities and generate benefits for the nuclear microreactor industry. With resilient embedded sensors in development in other programs funded by the US Department of Energy’s Office of Nuclear Energy and elsewhere, the work described herein builds upon previously funded efforts to mature non-destructive testing technology that relates measured vibrational signatures to structural changes, using a combination of new experimental measurements and machine learning processing. Building on past successful demonstrations of predictive workflows to identify structural changes in a hexagonal stainless steel test article with excellent acoustic propagation, we first performed baseline characterization on graphite samples with canonical geometries to ensure compatibility and confidence in the applied techniques for a material with distinctly different mechanical properties. In contrast to efforts in previous years, we worked exclusively with unidirectional vibration data that is more comparable to those expected from the existing embedded sensor technologies which are suitable for deployment in a reactor setting. Established acoustic and modern machine-learning-based characterization approaches were applied to the resulting datasets from these simple geometries. Both approaches were found to be highly capable of detecting even small geometric irregularities amongst nominally identical samples. As such, we then moved to testing these approaches for detection of artificial local stress perturbations introduced into a more complex geometry: a hexagonal block with drilled holes. A main outcome of this work is that a generalizable ML workflow can be used to detect and predict the characteristics of small artificial anomalies in a graphite component with a relevant geometry. While this work was performed using surficial vibration data, we expect the approach to be flexible and viable for other monitoring scenarios, such as those with different arrangements or types of sensor arrays. As compared to previously funded efforts, an existing ML workflow based on neural networks was enhanced through the addition of recently developed Fourier neural operators. As applied to previously collected and new vibration datasets, prediction accuracies of anomaly characterizations were greatly improved with minimal added computational cost. As trained on small durations of vibration data (tens of seconds) collected over a realistic number of locations, the model was able to reliably determine the presence of a subtle stress anomaly and begin to provide location estimates. Such an approach is likely to be viable for more relevant reactor damage scenarios for graphite components, such as progressive crack growth or creep.

36 MATERIALS SCIENCE↗