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DOE OSTI2024

ECAR-6580 Rev 0 ASME Section III, Division 5 Analysis of the MARVEL PCS and GVS Top Corner

The purpose of this Engineering Calculations and Analysis Report (ECAR) is to document the structural evaluation for part of the Microreactor Applications Research Validation and Evaluation (MARVEL) Primary Coolant System (PCS) and Guard Vessel System (GVS). For the PCS this relates specifically to the Distribution Plenum (DP), The Intermediate Heat Exchanger (IHX), and the Upper Downcomer (UD). For the GVS, this will include only the top corner that is machined into the DP Top Plate. These components will be evaluated using the 2021 version of ASME Section III, Division 5 [1] which is a design code that governs the construction of vessels, storage tanks, piping, pumps, valves, supports, core support structures and nonmetallic core components for use in high temperature reactor systems and their supporting systems. Materials at high temperature are subject to creep and fatigue mechanisms that require additional analyses that aren’t covered in ASME Section III, Division 1 rules. Division 5 contains two approaches: elastic or inelastic, however, additional Code Cases specific to Division 5, allow for an Elastic-Perfectly Plastic (EPP) approach. The components analyzed in this ECAR will use a combination of the elastic and EPP approach. Only Design and Service Levels A and B are evaluated in this ECAR. Service Level D evaluations for the entire PCS are documented in ECAR-6564, “MARVEL Project Primary Coolant System Pressure Vessel Stress Documentation” [2] and for the entire GVS are documented in ECAR-6574, “MARVEL Guard Vessel System FEA and ASME Analysis” [3]. The Design and Service Level A and B analyses for the PCS Downcomer piping and Core Barrel are documented in ANL-24/36, "Engineering Calculations and Analysis of the Core Barrel and Downcomer Piping in the MARVEL PCS” [4], and the GVS (except for the top corner) is in ECAR-6574, “MARVEL Guard Vessel System FEA and ASME Analysis.” See Section 2.0 for more detail on the analysis boundaries.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗
DOE OSTI2021

Topical Report – Findings on Subtask 2.7 – Wet ESP and Aerosol Testing at Coal Creek Station

Growing concerns over the impact of CO 2 emissions from combustion sources on global climate change have prompted numerous research and development projects aimed at developing cost-effective technologies for CO 2 capture. One family of technologies being demonstrated at pilot and full scale globally is postcombustion carbon capture (PCCC) systems that employ amine-based solvents. The captured CO 2 can be compressed and permanently stored underground or used for enhanced oil recovery. The proximity of North Dakota’s lignite-fired fleet of power plants to potential CO 2 storage options creates a unique atmosphere for PCCC within the state. However, the unique components present in lignite flue gas present a challenge for large-scale PCCC at North Dakota power plants by contributing to aerosol formation. Aerosols can negatively impact the long-term performance of amine-based solvents for CO 2 capture. Amine-based solvents are volatile, and flue gas particulate provides nucleation sites where amine vapors can condense as aerosols. Because aerosols cannot be easily captured at the column outlet using conventional technologies, the amine-laden aerosols escape the system and lead to accelerated solvent losses. Moreover, particulate components can chemically react with amines to form degradation products that can permanently deactivate the amine, cause fouling, and lead to hazardous emissions. Many of the elements that have been shown to catalyze solvent degradation are present in lignite coals and can exacerbate solvent replacement economics. Understanding this issue is critical to the implementation of solvent-based CO 2 capture systems as applied to lignite-fired generation systems. The Energy & Environmental Research Center (EERC) designed and carried out this project to fully characterize aerosol behavior with various control technologies installed to better optimize aerosol mitigation technology for CO 2 capture. To meet the goal of this project, the following objectives were identified: Determine the effectiveness of a wet electrostatic precipitator (WESP) on mitigating formation of problematic aerosols at Great River Energy’s Coal Creek Station, upstream of the PCCC system. Determine the effectiveness of the Mitsubishi Heavy Industries (MHI) proprietary amine emission reduction unit (AERU) as a postcapture solvent recovery system for reducing aerosol emissions and extending solvent life downstream of the PCCC system. Determine the impact of aerosols on the efficiency and degradation products of both commercial and advanced solvents within the PCCC system. Work was conducted at Coal Creek Station Unit 1 using a slipstream of flue gas from the outlet of the plant’s flue gas desulfurization (FGD) unit. Flue gas was routed through a pilot-scale FGD unit to remove SO 2 to very low levels (~1 ppm) and then through a direct contact cooler (DCC) to further cool the gas and to remove moisture. The gas exiting the DCC was then optionally routed through a WESP before passing to the CO 2 absorber columns. The MHI solvent was used to scrub CO 2 from the slipstream through a set of two absorber columns. The rich solvent was regenerated in a stripper column by heating to drive off captured CO 2 . Flue gas exiting the absorber column was routed to MHI’s proprietary AERU to recover entrained solvent. The system operated using a catch-and-release method where the CO 2 was separated to provide data on the process, but the captured CO 2 was released back into the host site stack. Particulate was measured, collected, and analyzed from multiple locations throughout the pilot-scale system. Unlike the performance observed in prior work, the inlet FGD and DCC did not remove significant particulate matter from the flue gas. This appears to be due to a difference in the nature of the particulate. The DCC seemed to increase particulate size and count, most likely owing to water condensing onto the surfaces of fly ash particles. When the WESP was operated, it achieved >95% particulate capture. Very little particulate matter or indications of solvent were detected at the AERU outlet. When operating with advanced KS 21 solvent, the particulate material at the AERU outlet was even further decreased. Solvent analysis showed that some species derived from flue gas and ash were slowly concentrating in the solvent over the duration of the test. The levels observed were reported to be within expected ranges and were not of concern to MHI. A high-level techno-economic assessment of installing CO 2 capture at Coal Creek Station suggested that, when using a standard monoethanolamine (MEA)-based solution with simple heat integration, the energy penalty to net generation would be 34%. The bulk of this was due to steam losses for regenerating solvent, followed by parasitic electrical demand for CO 2 compression and then by increased parasitic load for pushing flue gas through the absorber column. These demands could be decreased with a more advanced solvent that exhibits lower heat of regeneration and lower pressure drop than does a simple MEA solution. Further energy could be saved with more thorough heat integration to recover useful energy from the steam used for solvent regeneration. Installing a WESP was predicted to increase the cost of electricity by nearly $5/MWh. This would become cost-effective if solvent losses were roughly 10 times the baseline estimate when not using a WESP but could be returned to baseline by installing the WESP. Piping CO 2 for storage in more favorable geology could help with carbon capture and storage economics. Although storing off-site would necessitate construction of a CO 2 transport pipeline, the cost of this pipeline might be more than offset by reducing the number of wells required, the depths of the wells required, and the electrical demand for the CO 2 compressor. Additional factors that favor off-site storage costs include smaller expected CO 2 plume sizes, which translates to less monitoring and fewer landowner agreements. More detailed assessment of the specific geology in the region under and around Coal Creek Station would be needed to accurately assess the costs and benefits of different storage site options. This subtask was cofunded through the Energy & Environmental Research Center–U.S. Department of Energy Joint Program on Research and Development for Fossil Energy-Related Resources Cooperative Agreement No. DE-FE0024233. Nonfederal funding was provided by the North Dakota Industrial Commission.

Strege, Joshua↗
DOE OSTI2025

Building a new multiphysics workflow in MOOSE: application to tritium migration, trapping and advection in TMAP8

Fusion devices are anticipated to produce and consume several kilograms of tritium per year. This rare fuel resource is both highly mobile and radioactive, making tracking inventories a priority for operation and safety. The fusion safety program at the Idaho National Laboratory has been developing the Tritium Migration and Analysis Program (TMAP), of which the latest version is a MOOSE-based application. TMAP8 is verified against its predecessors and possesses additional multi-dimensional tritium migration modeling capabilities. As we extend its capabilities towards both whole device (in multiple dimensions) and whole plant (with multiple components) simulations, the syntax of inputs must become compact, descriptive, compatible with quality assurance processes, and as error-proof as achievable. The new Physics system developed MOOSE can set up equations and instantiating them on plant components. The system permits the automatic definition of complex discretization with a consistency between object parameters achieved programmatically. The Physics system can currently instantiate the equations for heat conduction and Navier Stokes weakly compressible flow. In MOOSE-terms, it automates the definition of kernels, boundary conditions, and several core and helper materials and fields. As part of this effort, Physics classes were developed for tritium migration, trapping and advection within either a multi-dimensional Navier Stokes fluid dynamics simulation, or a 1D thermal hydraulics piping system. In this presentation, we will showcase the new syntax, its application to several verification and validation cases which were already studied using the classical TMAP8 syntax, and a demonstration of the new coupling capabilities for the migration of tritium into blanket coolant channels and the subsequent advection into the coolant loop.

70 - PLASMA PHYSICS AND FUSION TECHNOLOGY↗
DOE OSTI2022

Anticipating water distribution service outages from increasing temperatures

With projected temperature increases and extreme events due to climate change for many regions of the world, characterizing the impacts of these emerging hazards on water distribution systems is necessary to identify and prioritize adaptation strategies for ensuring reliability. To aid decision-making, new insights are needed into how water distribution system reliability to climate-driven heat will change, and the proactive maintenance strategies available to combat failures. To this end, we present the model Perses, a framework that joins a water distribution network hydraulic solver with reliability models of physical assets or components to estimate temperature increase-driven failures and resulting service outages in the long term. A theoretical case study is developed using Phoenix, Arizona temperature profiles, a city with extreme temperatures and a rapidly expanding infrastructure. By end-of-century under hotter futures there are projected to be 1%–5% more pump failures, 2%–5% more PVC pipe failures, and 3%–7% more iron pipe failures (RCP 4.5–8.5) than a baseline historical temperature profile. Service outages, which constitute inadequate pressure for domestic and commercial use are projected to increase by 16%–26% above the baseline under maximum temperature conditions. The exceedance of baseline failures, when compounded across a large metro region, reveals potential challenges for budgeting, management, and maintenance. An exploration of the mitigation potential of adaptation strategies shows that expedited repair times are capable of offsetting the additional outages from climate change, but will come with a cost.

54 ENVIRONMENTAL SCIENCES↗
DOE OSTI2025

Integration and commissioning plan of Full Flow Purifier at Muon Campus

The Full Flow Purifier for Fermilab’s Muon Campus uses a charcoal bed surrounded by a liquid nitrogen jacket to purify up to 240 g/s of helium gas. Fabrication by Ability Engineering Technology Inc. has been completed and the purifier delivered to Fermilab. It is the largest purifier to be used at Fermilab based on both capacity and size. A previous paper discussed the design of purifier for various operational conditions and horizontal shipping. The purifier is designed to withstand 5g force in vertical and 2g force in lateral and longitudinal directions. Transportation experience from vendor to Fermilab and within site is discussed. Integration of the purifier involved design and fabrication of a liquid nitrogen transfer line, regeneration system, and helium piping to connect it to Muon Campus cryogenic system. It also involved establishing electrical, instrumentation and controls connections to the system. Integration of the purifier is discussed in detail. The purifier is to be commissioned using up to 4 MYCOM helium compressors to supply helium and liquid nitrogen supplied by a 15,000 -gallon tank. Actual effectiveness of the 3-stream heat exchanger is to be estimated based on measured temperatures and flow rate. Impurity levels shall be monitored at inlet and outlet of the purifier. Theoretical adsorption capacity of the purifier is calculated based on the measured temperatures and flowrates and is compared to actual adsorption capacity over time.

Subedi, Jeewan [Fermilab]↗
DOE OSTI2025

Integration and commissioning plan of Full Flow Purifier at Muon Campus

The Full Flow Purifier for Fermilab's Muon Campus uses a charcoal bed surrounded by a liquid nitrogen jacket to purify up to 240 g/s of helium gas. Fabrication by Ability Engineering Technology Inc. has been completed and the purifier delivered to Fermilab. It is the largest purifier to be used at Fermilab based on both capacity and size. A previous paper discussed the design of purifier for various operational conditions and horizontal shipping. The purifier is designed to withstand 5g force in vertical and 2g force in lateral and longitudinal directions. Transportation experience from vendor to Fermilab and within site is discussed. Integration of the purifier involved design and fabrication of a liquid nitrogen transfer line, regeneration system, and helium piping to connect it to Muon Campus cryogenic system. It also involved establishing electrical, instrumentation and controls connections to the system. Integration of the purifier is discussed in detail. The purifier is to be commissioned using up to 4 MYCOM helium compressors to supply helium and liquid nitrogen supplied by a 60,000-liter tank. Actual effectiveness of the 3-stream heat exchanger is to be estimated based on measured temperatures and flow rate. Impurity levels will be monitored at inlet and outlet of the purifier. Theoretical adsorption capacity of the purifier is calculated based on the measured temperatures and flowrates and is compared to actual adsorption capacity over time.

Subedi, J. [Fermilab] (ORCID:0009000185837576)↗
DOE OSTI2023

Preliminary Development of Heat Transfer Model-Based Control Algorithms of Liquid Sodium Purification System: Advanced Sensors and Instrumentation Advanced Controls

Monitoring the operation of sodium purification system is essential for efficient operation of sodium fast reactors. In this work, a heat transfer model has been developed for monitoring the plugging meter and cold trap systems at the Mechanisms Engineering Test Loop (METL) liquid sodium facility at Argonne National Laboratory. The model of the purification system was developed by treating the respective aspects of the cold trap purification loop and plugging meter diagnostic loop as two separate control volumes using information from the METL piping and instrumentation diagram (P&ID). A model predictive controller was designed using first order differential equations with the specified boundary conditions. The system behavior was studied with a tuned optimized procedure using the internal cold trap temperature and plugging meter outlet temperature as control variables, and the air blower temperature as an independent variable respectively. Results of computer simulations obtained in this study compared favorably with experimental data showing very good reference tracking response with negligible overshoot as both plugging meter and cold trap physical models approach the setpoint.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2025

An ASME-Compliant Helium-4 Evaporation Refrigerator for the SpinQuest Experiment

This paper presents the design, safety basis, and commissioning results of a 1 K liquid helium-4 (4He) evaporation refrigerator developed for the Fermilab SpinQuest Experiment (E1039). The system represents the first high power helium evaporation refrigerator operated in a fixed target scattering experiment at Fermilab and was engineered to comply with the Fermilab ES&H Manual (FESHM) requirements governing pressure vessels, piping, cryogenic systems, and vacuum vessels. The design is mapped to ASME B31.3 (Process Piping) and the ASME Boiler and Pressure Vessel Code (BPVC) for pressure boundary integrity and overpressure protection, with documented compliance to FESHM Chapters 5031 (Pressure Vessels), 5031.1 (Piping Systems), and 5033 (Vacuum Vessels). This work documents the methodology used to reach compliance and approval for the 4He evaporation refrigerator at Fermilab which the field lacks. Design considerations specific to the high radiation target-cave environment including remotely located instrumentation approximately 20 m from the cryostat are summarized, together with the relief-system sizing methodology used to accommodate transient heat loads from dynamic nuclear polarization microwaves and the high-intensity proton beam. Commissioning data from July 2024 confirms that the system satisfies all thermal performance and safety objectives.

Roberts, Jordan D. [Virginia U.]↗
DOE OSTI2023

A New Proposal Generalized Predictive Control Algorithm With Polynomial Reference Tracking Applied for Sodium Fast Reactors

This paper proposes a generalized predictive control (GPC) with constraints and orthonormal Laguerre functions using the simplified model of the primary system (reactor core and intermediate heat exchanger (IHX)) of a prototypical sodium fast reactor (SFR). This paper develops a multiple-input multiple-output (MIMO) GPC with input constraints able to track polynomial references of any degree applied in coolant temperature difference across the core and fractional power. The manipulated variables of the GPC-SFR are the reactivity and the sodium flow rate of the primary and secondary pipes. Moreover, orthonormal Laguerre functions and step down condition number techniques were also applied to avoid the numerical ill-conditioning issue in quadratic programming of large systems. Thus, a GPC type-2 was designed to control fractional power, coolant temperature difference across the core and sodium tank temperature of the SFR primary system when temperature references change according to a linear ramp after reaching their steady-state operation, sustaining 100% power operation on the reactor. In order to analyze the load tracking capability of the GPC-SFR type-2, the load following from 100% fractional power (FP) to 60% FP at 0.8% FP/min rate is simulated. Constraints on the rate of coolant temperature difference across the core and reactivity were applied for the design safety. For comparison criteria, this paper compares the GPC-SFR type-2 with the GPC-SFR type-1, i.e., standard model predictive control (MPC), to verify the viability and superior performance of the proposal regarding: (a) ramp-tracking capability of temperature and load; (b) the rejections of a reactivity disturbance of -1 cent and a secondary sodium inlet temperature disturbance of +10°F; and (c) a simulation with uncertainty in reactor design. The simulations show that the GPC-SFR type-2 overcome the GPC-SFR type-1 robustness and performance.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2022

SMART: Simplified Melting And Rotation-joint Technology

Oil based parabolic trough solar power plants are the most commercially mature CSP technology. However, the upper limit of about 400°C of the current organic heat transfer fluid(HTF)significantly limits the future potential of the technology. Advances in parabolic trough receiver and collector technology have enabled higher operating temperatures of potentially 500°C or above. The search for an improved higher temperature HTF has identified inorganic molten salts, specifically the mix referred to as Solar Salt, a 60:40 mix of sodium nitrate and potassium nitrate salt. However, Solar Salt starts to freeze at about 240°C. This poses a significant challenge for large parabolic trough plants that could have many kilometers of header piping and hundreds of kilometers of receiver piping all filled with molten salt. Plants using molten salt need to be designed to minimize the risk of freezing and to be able to recover from freeze events. Studies and field experiments have shown that this appears to be feasible and the approach appears to have strong economic advantages over conventional trough plants. However, some technical challenges remain related to the use of molten salt in trough solar fields, the cost of the freeze recovery system is significant, and many still question whether the risk of using molten salt is worth the economic upside. In our view, the potential economic upside justifies the continued look at molten salt HTF in parabolic trough plants. The objective of this project was to address the key technical issue remaining, look for opportunities to reduce the cost of the freeze recovery system, and improve the general information and tools available for assessing the design, performance and economics of trough plants using molten salt HTF.

14 SOLAR ENERGY↗
DOE OSTI2020

Technical Qualification of New Materials for High Efficiency Coal-Fired Boilers and Other Advanced FE Concepts: Haynes® 282® ASME Boiler and Pressure Vessel Code Case

This DOE Fossil Energy project, FEAA117, addressed materials issues relevant to qualifying and deploying a Ni-base alloy for a new application in an advanced ultra-supercritical coal-fired boiler. The goal was the deployment of Haynes International alloy Haynes® 282® for applications in superheaters, reheaters, and steam delivery pipes, by completing base metal, cross-weld and all-weld metal mechanical testing needed for an ASME Boiler and Pressure Vessel Code Case and the associated microstructural analyses needed for assurance of boiler-relevant lifetimes. The alloy also is of interest for other applications including supercritical CO₂ power generation cycles. Tensile testing was completed from 20°-927°C on the three base metal alloy 282 heats, two sets of cross-weld specimens and all weld metal specimens. A total of 148 creep tests with over 565,000 h of cumulative testing was completed on base metal, cross-weld and all weld metal specimens. This project was performed with cost share from Haynes International.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2024

The MOOSE Thermal Hydraulics Module

The Multiphysics Object-Oriented Simulation Environment (MOOSE) is an open-source object-oriented finite element framework written in C++ (Lindsay et al., 2022). The Thermal Hydraulics Module (THM) is an optional MOOSE physics module that provides capabilities for studying thermal hydraulic systems. Its core capability lies in assembling a network of coupled components, for instance, pipes, junctions, and valves. THM provides several new systems to MOOSE to enable and facilitate thermal hydraulic simulations, most notably the Components system, which provides a higher-level syntax to MOOSE’s lower-level objects. This system is extensible by the user, but the current library primarily includes components based on a one-dimensional, single-phase, variable-area, compressible flow model, as well as heat conduction.

42 ENGINEERING↗
DOE OSTI2020

Design of Stand-Alone Cryomodule based on Superconducting Quarter-Wave Resonator

Present superconducting accelerators require a central refrigeration system and piping to distribute liquid helium and nitrogen. Stand-alone cryocooler-based systems are of significant interest both to scientific and industrial customers, as they allow applications at facilities where no cryogenic equipment and expertise exists, where it is undesirable to develop additional cryogenic systems, or where a mobile system that can be transported between beamlines or facilities is required. The technical challenge of this approach is to minimize the heat losses to the liquid helium so that commercially available, self-contained cryocoolers are able to handle the thermal load. This paper presents an improved design for a stand-alone quarter-wave resonator (QWR) cryomodule a based on commercially available cryocoolers. This cryomodule has a particular application in the ATLAS intensity upgrade project where it will house a 72.75 MHz QWR for beam energy adjustments to experimental areas, where no helium cryogenic systems exist. The described cryomodule may also be the critical part of a turnkey system with application to material processing, semiconductor manufacturing, food irradiation and homeland security. The development of low heat loss peripheral components reduces cost and widens applicability of the system. We will discuss the cryomodule and RF coupler designs, including numerical thermal and structural analyses.

43 PARTICLE ACCELERATORS↗
DOE OSTI2022

Study on Conduction Cooling of Superconducting Magnets for the ILC Main Linac

In the main linac of the International Linear Collider (ILC), superconducting magnets for beam focusing and steering will be located periodically in superconducting RF (SRF) cavity string for beam acceleration in common cryomodules. A concept of conduction cooling of the combined-functioned, splittable superconducting magnets has been proposed and investigated to adapt much different features and to meet different requirements for the superconducting magnet and SRF cavity in fabrication, assembly, and operation. It is required to integrate the superconducting magnet after the SRF cavity string assembly which completed under an ultra-clean environment. The magnet must be conductively cooled down through thermal links to a liquid helium supply pipe. According to this concept, a model magnet development was carried out in cooperation with Fermilab and KEK, and has been demonstrated in KEK superconducting RF test facility (STF). In addition, an important issue has been recently identified. High gradient SRF cavities naturally emit field emission electron flux from the inner surface, so-called dark current. It may pass through the subsequent SRF cavity string and penetrate into the superconducting magnets placed downstream. It may heat up the superconducting coils, and may cause a quench. Therefore, further study on reliable conduction cooling and to secure the superconducting magnet operation with a keeping sufficient safety margin is quite essential. In this paper, we report the installation, the improvement achieved in STF, and the R&D progress in the study on the conduction cooling of the superconducting magnet for the ILC main linac.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

Effects of additively manufactured surface roughness on small diameter plenums with multiple side discharges for high temperature gas turbine blade cooling applications

Combined heat and power (CHP) applications have significant environmental and economic benefits that are consistent with the goals of the U.S. Department of Energy (DOE). One area that is currently being studied includes the potential benefits of CHP turbine operation at higher turbine inlet temperatures. Internal cooling concepts enabled by additive manufacturing (AM) are of primary interest. Here, the effectiveness of internal cooling is hindered by many factors such as velocity distribution of the cooling air to the hot surface considering impingement cooling. To simulate cooling air exiting from a series of orifices for internal cooling in an airfoil, a straight smooth wall tubing with multiple side discharging orifices is used and compared to additively manufactured tubing (Ti6Al4V Grade 23) with orifice size and spacing as well as inner and outer diameters identical to the smooth wall tubing. Similar to flow discharging form perforated pipes, the flow discharged from individual orifices along the tubes in this study is found to be nonuniformly distributed, and the horizontal (axial direction) momentum can be observed from the experimental data. Discharge velocities have been measured with two-dimensional (2D) particle imaging velocimetry (PIV) and single element hot wire anemometry. Numerical analysis has also been conducted to predict the velocity distributions along the orifices in the smooth wall and additive manufacturing (AM) tubing, which are inherited with surface roughness. Numerical and measured results in this study are compared, presented, and discussed.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2023

Preconceptual Designs of Coupled Power Delivery between a 4-Loop PWR and 100-500 MWe HTSE Plants

This study develops a preconceptual design for the integration between a large-scale high-temperature electrolysis facility and a NPP. Two hydrogen facility sizes are considered: 100 MWnom and 500 MWnom. Both steam supply designs use cold reheat steam extraction as a heat source. A reboiler inside the protected area of the power plant transfers steam heat to the demineralized water supply for the hydrogen plant. After the heat transfer, the extracted steam condenses and returns to the condenser while the process steam routes out of the protected area to the electrolyzers. Electrical power is tapped off from the high voltage side of the GSU transformer, where it is then transported via a 345-kV transmission line to the hydrogen facility. Circuit breakers and disconnects are located at both ends of the transmission line. Step down transformers and miscellaneous switchgear/buses are located at the end of the transmission line inside the HTEF boundary. Control capabilities for the steam interfacing equipment and electrical dispatch are accessible from the Main Control Room, and protective relays for the transmission line are located inside the Relay Room. Computer modeling was performed for the thermal and electrical designs. PEPSE analysis provided the steady-state parameters for thermal extraction from the turbine cycle. These parameters were used to inform transients and size equipment in combination with Applied Flow Technology (AFT) Arrow and AFT Fathom modeling for steam and water piping, respectively. Electrical transients were analyzed using PSCAD. An ETAP model was used to evaluate power flow and short circuit, which enabled the sizing of transformers and protective equipment. A cost estimate was developed for both integration designs when considering plant separation distances of 250 m and 500 m. From these estimates, the modifications for thermal and electrical interfacing of a first-of-a-kind nuclear-integrated hydrogen facility are anticipated to cost between $60–250/kWnom., where the subscript “nom” refers to the nominal size of the hydrogen plant. On a thermal power basis, the thermal power has a cost of approximately $8/MWth for a 500 MWnom high temperature electrolysis plant located 500 m distant from the NPP. That value decreases to approximately $7.5/MWth for a 250 m separation distance between the hydrogen plant and the NPP. This value is lower than previous estimates of the cost of heat extracted from NPPs primarily because in this work the steam is extracted from cold reheat instead of the main steam line, which reduces the cost of the dispatched steam by approximately $3.5/MWth. Nuclear steam extraction can provide a profit avenue for many plants and is not restricted to hydrogen production. Ammonia production, oil refining, and paper production, among other industrial processes all require thermal energy, which can be provided by NPPs. Future work should look further at the details of thermal extraction for a variety of use cases. This can include increased levels of extraction and multiple simultaneous users. Additionally, site-specific studies should be performed to develop industry experience and improve cost accuracy.

08 HYDROGEN↗
DOE OSTI2021

HyPerPy (Hydrogen Extraction and Parabolic Trough Plant Performance Models using Python) [SWR-21-53]

The HyPerPy package consists of three scripts: 1) Model for Hydrogen Tracking in Parabolic Trough Power Plants, 2) Model for Receiver Performance, and 3) Model for Hydrogen Extraction Process. The power plant model (1) tracks hydrogen generation and transport within the circulating heat transfer fluid (HTF) of the power plant. This script is a transient, initial value simulation, in which the hydrogen concentration in the circulating HTF is 0 moles per cubic meter everywhere at time 0 seconds. Hydrogen concentration is calculated at discrete locations within the circulating HTF with 4-second time resolution. During each time step, the change in hydrogen concentration due to hydrogen generation and permeation is calculated for each location according to the local HTF temperature, vessel or piping properties, hydrogen concentration and partial pressure. This model predicts hourly hydrogen concentrations for typical operating days in the spring, summer, fall, and winter seasons. Data is used to create hourly mappings of hydrogen concentrations for a typical operating year. The receiver model (2) uses a 1-hour time step to estimate getter loading and annulus pressure. For each time step, the model uses HTF and ambient temperature data to estimate absorber tube, bellows, and getter temperatures for the time step. In addition, the model uses hourly HTF hydrogen concentrations that are generated by the power plant model (1), and annulus hydrogen pressure from the previous time step. With these data, the model calculates the moles of hydrogen permeating across the absorber tube and bellows during the time step. The net change in moles hydrogen is added or subtracted from the getter loading for the previous time step, and the hydrogen pressure is re-calculated based on getter loading and temperature. The model uses this algorithm to simulate hydrogen permeation and loading 24 hours per day, 365 days per year using seasonal temperature data. The model repeats these calculations for 25 years to create a mapping of receiver getter loading and annulus hydrogen pressure for four seasons of each year. The model for hydrogen extraction (3) estimates hydrogen extraction rates for a specific separation module configuration. The rate depends primarily on membrane area, vacuum pump performance, headspace gas flowrate to the membrane, and headspace gas hydrogen partial pressure. This model has two versions. The steady-state version predicts hydrogen extraction rates when the module is operating in separation mode. The dynamic version predicts hydrogen transfer through the membrane when the module is operating in sensor mode. The steady-state version is used with the plant model (1) to predict hydrogen partial pressures in the power plant when the extraction process is operating.

Glatzmaier, Gregory↗
DOE OSTI2023

Helium-3 Piping and Gas Handling Implementation for the Colossus milli-Kelvin Platform at Fermilab

Colossus is a large millikelvin platform that has a two-meter diameter mixing chamber plate. This uniquely large millikelvin platform utilizes a cryogenics plant to maintain progressively lower temperatures at each of the three upper stages and precool the lower three stages of the system. At the millikelvin stages, Colossus employs multiple commercially available dilution units to achieve millikelvin temperatures at the 100 mK and 20 mK stages. The incoming helium-3/helum-4 process fluid mixture for each dilution unit flows through tubes wrapped around copper posts attached to each of the upper stages of the system. These tubes function as capillary heat exchanger to reduce the temperature of the incoming helium mixture to the appropriate temperature at each stage.

James, C.↗