Results for “PELLETS” — Page 26

DOE OSTI2024

ROADRUNNER MiniFuel Experiment: Irradiation Target Design and Sample Characterization

High-density uranium nitride (UN) is a fuel candidate for several advanced nuclear reactor designs currently under development. Because there are limited UN performance data relative to fuel fabrication impurity and density variation, an irradiation campaign has been developed as part of a collaborative effort among the University of Texas at San Antonio (UTSA), Westinghouse Electric Company, Oak Ridge National Laboratory (ORNL), and Los Alamos National Laboratory (LANL) under the Nuclear Science User Facilities program. This project, entitled ROADRUNNER, or Research On ADvancing the peRformance of UraNium Nitrides in Extreme enviRonments, aimsto support UN fuel qualification for advanced reactors by investigating the impact of density and impurity variations on UN performance as a function of irradiation temperature and burnup. The MiniFuel experiment vehicle developed by ORNL, which leverages the High Flux Isotope Reactor, was selected to perform this accelerated separate-effects irradiation testing. The experiment test matrix consists of six MiniFuel targets containing miniature UN fuel disks, and targets three distinct burnup levels (37.5, 60, and 75 MWd/kg U) and three distinct temperatures (600, 900, and 1200°C). Neutronics and thermal analyses were performed to determine the experimental parameters needed to meet the desired irradiation conditions and to predict the experiment components temperatures. UN pellets were fabricated at LANL with tightly controlled parameters to produce specimens with three distinct densities and three levels of carbon content. The pellets were then thinned down by UTSA to the experiment-required thickness. The pre-characterization of the specimens includes density measurements, carbon and oxygen contents, microstructure analysis, and x-ray computed tomography. The selected specimens will be assembled into the MiniFuel experiment, and the first ROADRUNNER MiniFuel targets are intended for HFIR insertion during the Fall of 2024. After irradiation, the targets will be shipped to ORNL’s hot cell facility for disassembly. The post-irradiation examination on the fuel specimens includes fission gas release measurements, visual inspection, fuel swelling measurements, gamma spectroscopy, and microstructure analysis. The data collected post-irradiation will be used to develop fuel performance models.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Deployment of BISON models of fuel restructuring at high burnup and related fission gas behavior in UO 2

This milestone report details the advancements made in fiscal year 2024 under the Nuclear Energy Advanced Modeling and Simulation (NEAMS) program to improve the modeling of fission gas behavior in high burnup UO 2 nuclear fuel in the BISON fuel performance code. As nuclear fuel is pushed to higher burnups, significant microstructural changes occur within the fuel, including the formation of a high burnup structure (HBS) on the pellet rim and a dark zone deeper within the pellet. These regions, characterized by subgrain formation and increased pore densities, have critical implications for fission gas behavior and release, which are not well understood. The modeling capabilities in BISON did not adequately predict these phenomena, leading to an underestimation of fuel restructuring and - potentially - of fission gas release. To address these gaps, this milestone focused on three key objectives: (1) reviewing and assessing Sifgrs's capabilities for low burnup fuel, on which high burnup capabilities rely, (2) validating and expanding HBS fission gas modeling capabilities, including investigating mechanisms for fission gas release from HBS, and (3) expanding Sifgrs to enable modeling of dark zone formation and its effects on fission gas behavior. These objectives were achieved and are described herein. The achievements of this NEAMS milestone are significant for the industry's goal of burnup extension. The improved predictive modeling capabilities for both low- and high-burnup conditions enhance our understanding of fuel performance under both normal operations and transient scenarios. Although goals were reached, future work is necessary to validate these models against experimental data and quantify their accuracy in different conditions. In parallel, mechanistic modeling efforts should continue to extend and refine these capabilities to increase accuracy while reducing reliance on empirical models. This will ensure robust performance across a broader range of conditions.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

Fuel Performance Calculations of Tagged UO 2 MiniFuel Disks

Isotopic taggants are being considered as a novel form of forensic identifiers for nuclear fuels. As part of this effort, eighteen tagged MiniFuel disks were irradiated in the High Flux Isotope Reactor at Oak Ridge National Laboratory. In this work, the BISON fuel performance code was used to recreate the pellets and predict their behavior and their post-irradiation material properties. These predictions are to serve as a baseline to help investigators identify results of interest during post-irradiation examination of actual MiniFuel disks. The simulation methodology and models are described herein, along with the individual disk predictions. Several general trends were identified in this analysis. Based on the models, it is predicted that the pellets’ internal temperatures will rise over time, fission gas release will remain constant at around 1%, regardless of the burnup, and no grain growth will occur in any of the disks. The reasons for these predictions are discussed below. Probable shortcomings in the BISON predictions are addressed, and future work is proposed.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2025

Tantalum Experiments in Fully-Reflected Water-Moderated Triangular-Pitched U(6.90)O 2 Fuel Rod Lattices (1.02 cm Pitch)

The United States (US) Department of Energy (DOE) Nuclear Energy Research Initiative funded the design and construction of the Seven Percent Critical Experiment (7uPCX) at Sandia National Laboratories (SNL). The start-up of the experiment facility and the execution of the experiments described here were funded by the DOE Nuclear Criticality Safety Program. The 7uPCX is designed to investigate critical systems with fuel for light water reactors in the enrichment range above 5 % 235 U. The 7uPCX assembly is a water moderated and — reflected array of aluminum-clad U(6.90 %)O 2 fuel rods. Other critical experiments performed in the 7uPCX assembly are documented in LEU-COMP-THERM-078, LEU-COMP-THERM-080, LEU-COMP-THERM 096, LEU- COMP-THERM-097, LEU-COMP-THERM-101, LEU-COMP-THERM-102, and LEU-COMP-THERM-111. Applied interests in neutron-absorbing elements at epithermal and intermediate neutron energy ranges at DOE’s Hanford Site and Savannah River Site were identified through DOE Office of Environmental Management (EM) workshops and needs surveys performed in conjunction with the National Nuclear Security Administration/Nuclear Criticality Safety Program. In response, a team lead by Oak Ridge National Laboratory (ORNL) performed a study evaluating the use of 7uPCX for testing the epithermal cross sections of materials at SNL. This marked the inception of the set of experiments described here. The purpose of these experiments was to measure the effects of tantalum in nearly-critical systems. The tantalum was introduced into the fuel arrays as experiment rods within a central test region. The central test region was designed to target the epithermal neutron energy range by providing a dry cylindrical cavity constructed of aluminum and lined with 0.04 in (0.1016 cm) thick cadmium sheet. The central test region has an outer diameter of 3.75 in (9.525 cm) length of 31 in (78.74 cm) and can hold 85 tantalum rods nominally 0.25 in (0.635 cm) outside diameter and 31.25 in (79.375 cm) long. The critical experiments were done using a set of triangular-pitched grid plates fabricated for these experiments. The grid plate set accommodated a fuel array of a total of 2016 fuel rod positions on a pitch of 0.4 in (1.016 cm) in a series of 21 hexagonal rings positioned around the central test region. The fuel used in these experiments was fabricated using unirradiated 6.90 % enriched UO 2 fuel pellets from fuel elements designed to be used in the internal nuclear superheater section of the Pathfinder boiling water reactor operated in South Dakota by the Northern States Power Company in the 1960s. The fuel elements were obtained from The Pennsylvania State University where they had been stored for many years. The fuel pellets in those fuel elements were removed from the original Incoloy cladding and reclad in 3003 aluminum tubes and end caps for use in the experiments reported here. The eight cases in this experiment series were performed in 2024 in the Sandia Critical Experiments (SCX) at the Sandia Pulsed Reactor Facility by varying the number of fuel rods in the critical assembly. The personnel involved in conducting these experiments included David Ames, Elijah Lutz, Beth Hanson, Patrick Ward, Jason Soares, and Augie Chapa from SNL, as well as Mathieu Dupont and B.J. Marshall from ORNL. Case 1 had no tantalum experiment rods. Case 2 had seven tantalum rods in the center of the central test region. Case 3 had 18 tantalum rods in the third hexagonal ring of the central test region. Case 4 had 19 tantalum rods in the center of the central test region. Case 5 had 30 tantalum rods in the outer most positions of the central test region. Case 6 had 37 tantalum rods in the center of the central test region. Case 7 had 61 tantalum rods in the center of the central test region. Case 8 had 85 tantalum rods filling all positions in the central test region. All eight critical experiments are judged to be acceptable as benchmark experiments.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2024

Metallic Coating of Cerium Oxide Microspheres

The ability to remove heat is paramount to nuclear fuel performance and longevity. Retaining fission product and separating fuel from reactor coolant and the environment is also necessary to prevent radiological contamination. Conventional nuclear fuel for commercial light water reactors and radioisotope power systems (RPS) is composed of oxide powders pressed into a pellet (cm-scale) and then sealed into a metal cladding to confine the fuel. What typical fuels lack is a method to surround each particle of nuclear fuel in metal, thus providing a more intimate protection layer for accident tolerance and boosting the thermal extraction from the fuel element. In such a way, metal-coated fuel particles increase heat extraction efficiency over clad-pellet designs while increasing the accident tolerance of the fuel. Metal oxide microspheres have wide-ranging applications, including the realm of fuels for nuclear reactors and RPS. Microspheres of uranium oxide/uranium carbide, mixed uranium/plutonium oxides, transuranics, and thorium fuels have been extensively studied. Pacific Northwest National Laboratory has also demonstrated the production of 238 PuO 2 microspheres for RPS applications. Metal-coated oxide microsphere fuels may also be attractive for other applications such as nuclear thermal rockets, future nuclear reactor designs, and catalysts.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2026

First-principles Study of the Tritium Species Diffusion Across Ni-Zircaloy-4 Getter Interface

Tritium is a critical fuel component for experimental nuclear fusion reactors (like tokamaks), typically used in combination with deuterium. In tritium-producing burnable absorber rods (TPBARs), due to its high lithium density, LiAlO2 is used in the form of an annular ceramic pellet enriched with the Li_6 isotope located between the Zircaloy-4 liner and nickel-plated Zircaloy-4 tritium getter. Employing DFT, we explored the tritium diffusion across the pellet and getter.

36 MATERIALS SCIENCE↗

DOE OSTI2025

UN Synthesis, Fabrication, and Characterization and UC Oxidation Study in support of Advanced LEU Fuel Concepts

Uranium nitride and carbide-based fuels are proposed for use in advanced LEU fuel systems. This report details recent development work to study synthesis, sintering and fabrication methods for single phase UN in monolithic geometries. These samples were intended to support a variety of irradiation testing conditions by tailoring enrichment, geometry, and compositional requirements. Two methods were under evaluation for synthesizing uranium nitride powder – carbothermic reduction-nitridation (CTR-N) of UO 2 powder feedstock and hydride-dehydride/nitridation (HDN) of uranium metal feedstock. Pellets were fabricated from powder feedstocks via conventional pressing and sintering methods. As-fabricated feedstocks and pellets were evaluated via X-ray diffraction (XRD) for phase purity and sintered materials were characterized for density. Both the CTR N and the HDN methods were successfully demonstrated as an effective process for fabricating phase pure UN. Additionally, results from machining efforts for UN are detailed. This report also contains information on a study trying to elucidate the oxidation mechanisms of sintered uranium carbide samples fabricated from feedstock synthesized via an arc-melting method.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2024

KBase Narrative - Porphyromonadaceae sp. W3.11 genome

Narratives for The phenotype and genotype of fermentative prokaryotes This is the Narrative for Porphyromonadaceae sp. W3.11. A complementary Narrative for Lachnospiraceae sp. C1.1 is available here. This is the Narrative for Lachnospiraceae sp. C1.1. A complementary Narrative for Porphyromonadaceae sp. W3.11 is available here. Background and Isolation This Narrative and its complementary Narrative contain assembly and annotation of two bacterial isolates that were isolated by our laboratory from the rumen of a Holstein heifer. All procedures with animals have been approved by University of California Davis’s Institutional Animal Care and Use Committee. Rumen contents were collected through a rumen fistula and strained through two layers of cheesecloth into a bottle. The bottle was sealed to exclude air and maintained at 39°C. Contents were brought to the laboratory and bubbled under O2-free CO2 within 15 min. At the laboratory, serial dilutions were made with anaerobic dilution solution for Lachnospiraceae sp. C1.1 and propionibacterium diluent for Porphyromonadaceae sp. W3.11 (table S2). Aliquots (0.1 ml) of each dilution were injected into anaerobic bottle plates (1) containing 9 ml of LH medium (table S2). After incubation at 37°C for 7 days, isolated colonies were picked. Lachnospiraceae sp. C1.1 was picked from a bottle inoculated with a 104 dilution of rumen contents, and Porphyromonadaceae sp. W3.11 was picked from a bottle inoculated with a 103 dilution. After initial isolation, these organisms were purified by growing on anaerobic roll tubes (2) and picking isolated colonies. We performed de novo sequencing of Lachnospiraceae sp. C1.1 and Porphyromonadaceae sp. W3.11. Aliquots of liquid culture (9 and 1.5 ml, respectively) were collected by syringe and centrifuged (21,000g for 10 min at 4°C). Cell pellets were submitted to Molecular Research LP for DNA extraction, library preparation, and sequencing. After resuspending pellets in 180 µl of ATL buffer (Qiagen), DNA was extracted using the MagAttract HMW DNA Kit (Qiagen). DNA was eluted in 100 µl of AE buffer (Qiagen) and then cleaned using the DNEasy PowerClean Pro Cleanup Kit (Qiagen). DNA was then sheared using the Covaris g-TUBE (Covaris). Sequencing libraries were prepared using the SMRTbell Express Template Prep Kit 2.0 (Pacific Biosciences) and 1500 ng of the sheared and purified DNA. The SMRTbell libraries were size-selected (>6 Kb) using a BluePippin instrument (Sage Science) and 0.75% agarose gel. Libraries were then sequenced using the PacBio Sequel II (Pacific Biosciences) platform and a 30-hour movie time. Narrative Summary In these Narratives, we filtered low-quality reads using Trimmomatic (v0.36), assembled filtered reads with SPAdes (v3.15.3), and then checked completeness and contamination of the assembled genomes with CheckM (v1.0.18). Statistics for sequencing and assembly are in table S3. Using the assembled contigs (genomes), we called genes and annotated them. Protein-coding genes were called using Prodigal (v2.6.3) (3) locally or using KBase via RASTtk (v1.073), with identical results. Genes were annotated with KO IDs using KAAS (4). They were further annotated with pfam and TIGRFAM IDs using KBase and the Annotate Domains in a Genome app. We classified putative genes for hydrogenases using HydDB. Genes for 16S ribosomal RNA (rRNA) were called using RASTtk (v1.073) in KBase. The contigs (genomes) were analyzed to determine whether they belonged to new species. Taxonomy was assigned using GTDB-Tk (v1.7.0) in KBase. The identity of 16S rRNA genes to other organisms was found using EzBioCloud (5). Values of digital DNA-DNA hybridization (dDDH) were found with Type (Strain) Genome Server (6). These analyses suggest that Lachnospiraceae sp. C1.1 and Porphyromonadaceae sp. W3.11 represent novel species or genera. GTDB-Tk assigned Lachnospiracae sp. C1.1 to family Lachnospiraceae and genus NK4A144, which contains no type strains. It assigned Porphyromonadaceae sp. W3.11 to Porphyromonadaceae and genus Porphyromonas_A. Values of 16S rRNA identity and dDDH with respect to type strains were low (table S4). Although more phenotypic data are needed, available evidence supports assignment of genomes to new species or genera. Related publication Hackmann TJ, Zhang B. The phenotype and genotype of fermentative prokaryotes. Sci Adv. 2023 Sep 29;9(39):eadg8687. doi: 10.1126/sciadv.adg8687. Epub 2023 Sep 27. PMID: 37756392; PMCID: PMC10530074.

Hackmann, Timothy↗

DOE OSTI2024

KBase Narrative - Lachnospiraceae sp. C1.1 genome

Narratives for The phenotype and genotype of fermentative prokaryotes This is the Narrative for Porphyromonadaceae sp. W3.11. A complementary Narrative for Lachnospiraceae sp. C1.1 is available here. This is the Narrative for Lachnospiraceae sp. C1.1. A complementary Narrative for Porphyromonadaceae sp. W3.11 is available here. Background and Isolation This Narrative and its complementary Narrative contain assembly and annotation of two bacterial isolates that were isolated by our laboratory from the rumen of a Holstein heifer. All procedures with animals have been approved by University of California Davis’s Institutional Animal Care and Use Committee. Rumen contents were collected through a rumen fistula and strained through two layers of cheesecloth into a bottle. The bottle was sealed to exclude air and maintained at 39°C. Contents were brought to the laboratory and bubbled under O2-free CO2 within 15 min. At the laboratory, serial dilutions were made with anaerobic dilution solution for Lachnospiraceae sp. C1.1 and propionibacterium diluent for Porphyromonadaceae sp. W3.11 (table S2). Aliquots (0.1 ml) of each dilution were injected into anaerobic bottle plates (1) containing 9 ml of LH medium (table S2). After incubation at 37°C for 7 days, isolated colonies were picked. Lachnospiraceae sp. C1.1 was picked from a bottle inoculated with a 104 dilution of rumen contents, and Porphyromonadaceae sp. W3.11 was picked from a bottle inoculated with a 103 dilution. After initial isolation, these organisms were purified by growing on anaerobic roll tubes (2) and picking isolated colonies. We performed de novo sequencing of Lachnospiraceae sp. C1.1 and Porphyromonadaceae sp. W3.11. Aliquots of liquid culture (9 and 1.5 ml, respectively) were collected by syringe and centrifuged (21,000g for 10 min at 4°C). Cell pellets were submitted to Molecular Research LP for DNA extraction, library preparation, and sequencing. After resuspending pellets in 180 µl of ATL buffer (Qiagen), DNA was extracted using the MagAttract HMW DNA Kit (Qiagen). DNA was eluted in 100 µl of AE buffer (Qiagen) and then cleaned using the DNEasy PowerClean Pro Cleanup Kit (Qiagen). DNA was then sheared using the Covaris g-TUBE (Covaris). Sequencing libraries were prepared using the SMRTbell Express Template Prep Kit 2.0 (Pacific Biosciences) and 1500 ng of the sheared and purified DNA. The SMRTbell libraries were size-selected (>6 Kb) using a BluePippin instrument (Sage Science) and 0.75% agarose gel. Libraries were then sequenced using the PacBio Sequel II (Pacific Biosciences) platform and a 30-hour movie time. Narrative Summary In these Narratives, we filtered low-quality reads using Trimmomatic (v0.36), assembled filtered reads with SPAdes (v3.15.3), and then checked completeness and contamination of the assembled genomes with CheckM (v1.0.18). Statistics for sequencing and assembly are in table S3. Using the assembled contigs (genomes), we called genes and annotated them. Protein-coding genes were called using Prodigal (v2.6.3) (3) locally or using KBase via RASTtk (v1.073), with identical results. Genes were annotated with KO IDs using KAAS (4). They were further annotated with pfam and TIGRFAM IDs using KBase and the Annotate Domains in a Genome app. We classified putative genes for hydrogenases using HydDB. Genes for 16S ribosomal RNA (rRNA) were called using RASTtk (v1.073) in KBase. The contigs (genomes) were analyzed to determine whether they belonged to new species. Taxonomy was assigned using GTDB-Tk (v1.7.0) in KBase. The identity of 16S rRNA genes to other organisms was found using EzBioCloud (5). Values of digital DNA-DNA hybridization (dDDH) were found with Type (Strain) Genome Server (6). These analyses suggest that Lachnospiraceae sp. C1.1 and Porphyromonadaceae sp. W3.11 represent novel species or genera. GTDB-Tk assigned Lachnospiracae sp. C1.1 to family Lachnospiraceae and genus NK4A144, which contains no type strains. It assigned Porphyromonadaceae sp. W3.11 to Porphyromonadaceae and genus Porphyromonas_A. Values of 16S rRNA identity and dDDH with respect to type strains were low (table S4). Although more phenotypic data are needed, available evidence supports assignment of genomes to new species or genera. Related publication Hackmann TJ, Zhang B. The phenotype and genotype of fermentative prokaryotes. Sci Adv. 2023 Sep 29;9(39):eadg8687. doi: 10.1126/sciadv.adg8687. Epub 2023 Sep 27. PMID: 37756392; PMCID: PMC10530074.

Hackmann, Timothy↗

DOE OSTI2022

Melting Behavior of Conventional and Hydrogen-Reduced DRI in a Simulated EAF Steel Bath

The melting behavior of carbon-free direct reduced iron (DRI) produced by hydrogen reduction has been investigated in a simulated electric arc furnace (EAF) melting environment. A testing apparatus was created to document the melting rates under various bath conditions in slag and steel. This investigation is specific to pellets melted in a steel bath. A model was developed to simulate the shell growth and melting rate of a non-reactive DRI pellet in molten steel. Data acquired from preliminary experiments are utilized to validate the model. This investigation sheds light on the potential effects of melting hydrogen-reduced DRI in the EAF.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Bypassing Energy Barriers in Fiber-Polymer Torrefaction

The amount of waste generation has been increasing with a significant amount being landfilled. These non-recyclable wastes contain large number of fiber and plastic wastes which can be treated with thermal processes to turn them into energy sources since they have high calorific values, are abundant and usually tipping fees are paid to handle them. This paper studied the torrefaction of non-recyclable paper (fiber) wastes, mixed plastic wastes (MPW) and their blends at different ratios in the temperature range of 250–400°C through thermogravimetric analysis (TGA). The solid residues after the experiments were analyzed by nuclear magnetic resonance (NMR) spectroscopy. Significant synergy between fiber and MPW were observed at the range 250–300°C, showing both increase in the reaction rate as well as the overall mass loss. At 250°C, the maximum mass loss rate was more than two times higher and the mass loss at the end of the experiments were also much higher compared to the expected results. In addition, synergy was weakened with an increase of temperature, disappearing at 400°C. The existence of such interactions between fiber and plastic wastes indicates that the natural energy barriers during the individual torrefaction in paper waste or plastic waste could be bypassed, and the torrefaction of fiber and plastic blend can be achieved at lower temperatures and/or shorter residence times. The MPW and fiber wastes were also compounded by extrusion (to produce pellets) at 220°C with different blend ratios. The fiber-MPW pellets from extrusion were characterized by IR spectroscopy, rheology, thermal analysis and flexural properties and showed significant chemical changes from the non-extruded blends at the same ratios. From IR characterization, it was found that there was significant increase in hydroxyl (OH) group on account of the carbonyl (C = O) and etheric (C-O-C) groups. The interaction between paper and MPW can be attributed to the plastic polymers acting as a hydrogen donor during the reactive extrusion process. Synergistic effects were also found from mechanical and rheological properties.

09 BIOMASS FUELS↗

DOE OSTI2024

Energy-based break-even transportation distance of biomass feedstocks

The distance a solid biomass feedstock could be used to transport the feedstock when used as biobased fuel is critical information for transportation analysis. However, this information is not available. The break-even transportation distance (BTD) of various fuels from biomass feedstocks and fossil sources was analyzed for truck, rail, and ship transport modes based on bulk density, moisture content, and specific energy. Fourteen different biomass feedstocks, such as crop residues (e.g., corn stover), woody biomass (e.g., wood chips), including thermally pretreated (torrefied) and densified forms (pellets), cattle feedlot compost, and three standard fossil fuels, namely, coal, lignite, and diesel, were considered for BTD analysis and comparison. The BTD values were derived by comparing the energy content of biomass feedstocks with the energy expended in transporting the fuels through selected transportation modes. For ready reference, an alternative derivation of BTD equations and example calculations were also presented. Among the biomass feedstocks, torrefied pellets had the highest BTD (4.16 × 10 4 , 12.47 × 10 4 , and 54.14 × 10 4 km), and cattle feedlot compost had the lowest BTD (1.29 × 10 4 , 3.88 × 10 4 , and 9.23 × 10 4 km), respectively, for truck, rail, and ship. Higher bulk density and higher specific energy of the biomass feedstocks increased the BTD for all modes of transport. Transport is most efficient when mass-limited. Biomass feedstock bulk densities where transportation becomes mass-limited are 223, 1,480, and 656 kg/m 3 for truck, rail, and ship, respectively. Truck transport is typically mass-limited (payload limit restriction; increased BTD), whereas rail transport is entirely volume-limited (cargo space restriction; decreased BTD), and ship transport is mostly volume-limited for biomass feedstocks and mass-limited for densified biomass feedstocks. Ship transport is the most efficient, followed by rail and truck; on average for the materials (17) studied, rail is 3.1 times and ship is 9.2 times the truck's BTD. Based on the bulk density and higher specific energy of the biomass feedstocks, regardless of the refinery location, interstate truck transport of these feedstocks is not a limiting factor in the bio-refining process., with the studied biomass feedstock BTD per truckload representing between 0.89 and 2.88 times the US perimeter.

09 BIOMASS FUELS↗

DOE OSTI2022

Effect of Remnant Carbon and Etching of Particles on Pyrolysis Bonded Silicon Carbide (PBSC)

Silicon carbide (SiC) formed through pyrolysis of preceramic polymers loaded with SiC particles has gained significant attention for applications such as coatings, composite matrix modifications, and most importantly additive manufacturing. This work presents combined synchrotron XRD, Raman spectroscopy, scanning electron microscopy, nano-indentation, and Vickers indentation of pyrolysis bonded SiC to shed light on the changes of composition and mechanical properties of these materials. Characterization was performed on samples that were heat treated ranging from the synthesis 850 °C up to 1500 °C. Pre-treatments of the powders prior to pellet synthesis, such as heat treatment and etching using a hydrofluoric acid (HF), were investigated. It is shown that the degradation of mechanical properties when exposed to higher temperatures is due to the burnout of amorphous carbon clusters remnant of the pyrolysis process of the preceramic polymer. Furthermore, prior HF etching and removal of the native oxide layer of the powders showed improved density and hardness values in the final pellets. The average Vickers hardness of the control samples were 4.59 GPa and later 3.74 GPa when exposed to 1500 °C, while the samples synthesized using powders that were etched with HF had an average hardness value of 9.37 GPa and later 6.86 GPa when exposed to 1500 °C.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2022

On the Sintering Behavior of Nb2O5 and Ta2O5 Mixed Oxide Powders

A mixed oxide system consisting of Nb2O5 and Ta2O5, was subjected to annealing in air/hydrogen up to 950 °C for 1–4 h to study its sintering behavior. The thermogravimetric–differential scanning calorimetry (TGA–DSC) thermograms indicated the formation of multiple endothermic peaks at temperatures higher than 925 °C. Subsequently, a 30% Ta2O5 and 70% Nb2O5 (mol%) pellet resulted in good sintering behavior at both 900 and 950 °C. The scanning electron microscope (SEM) images corroborated these observations with necking and particle coarsening. The sintered pellets contained a 20.4 and 20.8% mixed oxide (Nb4Ta2O15) phase, along with Ta2O5 and Nb2O5, at both 900 and 950 °C, indicating the possibility of the formation of a solid solution phase. In situ high-temperature X-ray diffraction (XRD) scans also confirmed the formation of the ternary oxide phase at 6 and 19.8% at 890 and 950 °C, respectively. The Hume–Rothery rules could explain the good sintering behavior of the Ta2O5 and Nb2O5 mixed oxides. An oxide composition of 30% Ta2O5 and 70% Nb2O5 (mol%) and a sintering temperature of 950 °C appeared adequate for fabricating well-sintered oxide precursors for subsequent electrochemical polarization studies in fused salts.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Magnetic feed material and its use in producing bonded permanent magnets by additive manufacturing

A method for producing magnet-polymer pellets useful as a feedstock in an additive manufacturing process, comprising: (i) blending thermoplastic polymer and hard magnetic particles; (ii) feeding the blended magnet-polymer mixture into a pre-feed hopper that feeds directly into an inlet of a temperature-controlled barrel extruder; (iii) feeding the blended magnet-polymer mixture into the barrel extruder at a fixed feed rate of 5-20 kg/hour, wherein the temperature at the outlet is at least to no more than 10° C. above a glass transition temperature of the blended magnet-polymer mixture; (iv) feeding the blended magnet-polymer mixture directly into an extruding die; (v) passing the blended magnet-polymer mixture through the extruding die at a fixed speed; and (vi) cutting the magnet-polymer mixture at regular intervals as the mixture exits the extruding die at the fixed speed. The use of the pellets as feed material in an additive manufacturing process is also described.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Large-scale continuous carbon/glass fiber additive-compression molded composites

Additive Manufacturing (AM) or 3-D printing has advanced from small-scale desktop printers to large-scale printers. Most of the present large-scale printers utilize feedstock materials in the form of pellets to create composite structures. To create structurally robust composite parts, reinforcements in the form of short fibers (carbon or glass) are often used to impart mechanical properties to the printed parts. However, poor mechanical properties in Z-direction and high porosity of pellets-based printed composites compared to composite manufactured using traditional methods are serious concerns. The authors report a combined approach in the present work, where fiber reinforced composites are printed with a high-throughput continuous fiber deposition method followed by a secondary compression molding process. A specially designed end-effector mounted on a robotic arm is used to print composite preforms. Continuous comingled fibers (Thermofiber 12K CF-PA12, Thermofiber 12K S2-PA12, and Hybrid Thermofiber 12K CF-PA12+PEEK PA6) embedded in the thermoplastic nylon matrix are printed to create composite preform plaques. The printed preforms were further compression molded (CM) using a hydraulic hot-press to create highly consolidated composite parts. The mechanical properties of the continuous fiber composites produced by this combined approach are improved significantly due to the highly aligned continuous fibers and reduced porosity. Flexural strength, flexural modulus, and tensile modulus of AM-CM Thermofiber 12K CF-PA12 UD sample were 615.37 MPa, 75.65 GPa, and 122.23 GPa, respectively.

Kumar, Vipin↗

DOE OSTI2021

Destructive Examination of a FeCrAl-UO 2 Irradiation Test

Several destructive postirradiation examinations were performed on an irradiation specimen that coupled an early iron-chromium-aluminum (FeCrAl) candidate alloy cladding with UO2 pellets. This irradiation test was designed to investigate the early life performance and compatibility of the FeCrAl-UO 2 cladding-fuel system under prototypic light water reactor neutronic conditions. Additionally, these tests were expected to provide neutron irradiated samples for severe accident testing of this fuel system. The irradiation studied in this work was part of the ATF-1 series of drop-in style irradiations performed in the Idaho National Laboratory Advanced Test Reactor. The rodlet studied in this work is one of three similar rodlets irradiated in ATF-1 that had approximately 7.6 cm of cladding machined from a wrought FeCrAl alloy and fueled with a 6.1 cm stack of UO 2 pellets. The outer diameter of the cladding was ~0.94 cm and the inner diameter was ~0.83 cm. After irradiation and non-destructive examination in Idaho this rodlet was shipped to the Oak Ridge National Laboratory hot-cells for further examination. The irradiated rodlet was sectioned into several samples for microstructural, micromechanical, and severe accident testing. During sectioning, it was noted that the fuel was not firmly bonded to the cladding and could be readily removed from small cladding slices. Microstructural characterization of fuel cross sections also revealed no significant interaction between the fuel and the cladding. Samples were also prepared for microhardness testing. To prepare for high temperature oxidation testing, the fuel was dissolved from segments of the cladding. High temperature oxidation testing of cladding segments was performed at 1200°C and 1300°C in a steam environment. Comparisons between the oxidation of this FeCrAl alloy in its neutron irradiated state, as-fabricated state, and the oxidation of Zircaloy-2 are made. The oxidation testing will be followed by ring compression testing to evaluate ductility. The microstructure of the samples after oxidation and ring compression testing will also be analyzed.

Harp, Jason↗

DOE OSTI2022

Role of sustainable biomass markets in forest conservation

When properly implemented, the production of bioenergy using wood pellets can play a role in addressing threats related to biodiversity and climate change. Reduction in forest loss and degradation is fostered by the integration of sustainable pellet production with other forest markets and strategies to implement nature-based solutions. Local stakeholders should be engaged to devise management practices appropriate for the location and context. Market incentives for sustainable biomass production help conserve forests.

09 BIOMASS FUELS↗