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All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Modeling and Simulation of Fuel Dispersal During the Loss-of-Coolant Accident

This document is the compilation of the milestone portion to a larger end of project NEUP report. The executive summary of the modeling portion is provided below: In the event of cladding rupture during a postulated LOCA in a pressurized water reactor, fuel particles, along with fission gases, can be expelled into the reactor core from the fractured fuel rod, a phenomenon referred to as fuel dispersal. The initial stage of fuel dispersal is strongly influenced by the high-pressure ejection of fuel fragments, the size and geometry of the ruptured cladding, and the depressurization history of the fuel rod during the postulated LOCA transient. Depending on the location of the burst orifice relative to the quench front, the dispersal event represents an intricate three-phase flow and heat transfer phenomenon, where high-temperature fuel particles carried by the fission gases interact with the coolant within the narrow subchannels of the fuel assemblies, inducing localized phase change. Given the unique multiphysics nature of this phenomena, the current study develops a dedicated computational framework to predict the mass distribution and cooling of dispersing fuel particles, facilitating post-accident assessment and management of the fuel assemblies. Considering the scale of nuclear reactor applications, a continuum three-fluid model is proposed for simulating the transport of solids within the reactor core. With high-temperature fuel fragments within the liquid media, nucleation sites inducing phase changes are dispersed within the flow domain. Coupled with the fact that the transient dispersal event occurs on different time scales than other three-phase flow applications, this study derives a time-averaged three-fluid flow model without losing generality. The assumptions regarding the continuum treatment of the solid phase and the modeling of fuel dispersal behavior are incorporated to simplify the governing equations and derive applicable closure relations. The computational validation of the model was conducted using adiabatic experimental results obtained from ongoing research at Oregon State University, focusing on characterizing fuel dispersal behavior during simulated LOCA conditions. Settlement characteristics of the solids, quantified by the probability distribution of equivalent particles, closely matched the probability density functions reported in experimental studies. The transport of fuel particles within a scaled 5 × 5 lattice of a pressurized-water reactor rod bundle geometry was modeled through a two-fluid Eulerian framework. The required boundary conditions were evaluated from the fuel performance code BISON in a postulated large-break LOCA scenario. The modeling framework considered solid fuel particles as granular matter, interacting with the gaseous dry steam phase and fission gases through the governing interfacial momentum exchange between the participating fluids. The simulation results provided the volume fraction of the solids obtained at the bottom surface of the enclosing tank geometry. Postulated LOCA leading to fuel dispersal phenomena involves the strong coupling between fuel thermomechanics, cladding deformation, thermal-hydraulics, and fuel particle transport. Incorporation of such a strong coupling in numerical simulation is performed by coupling the multiphysics solvers. In the case of fuel dispersal, a strong coupled simulation can be performed by coupling the BISON code for fuel performance, the TRACE code for system-level thermal hydraulics, and fuel particle transport in Multiphysics Object-Oriented Simulation Environment (MOOSE). For such intricate infrastructure, the MOOSE Framework eases the data transfer between codes. The recent version of MOOSE has incorporated the Navier-Stokes module for the fluid flow. An exploratory exercise was done to gain familiarity with finite volume capabilities in the MOOSE framework to incorporate the Spalart-Allmaras (SA) turbulence model. New finite-volume and auxiliary kernels were introduced to assemble the SA transport equation, compute turbulent viscosity, and evaluate wall distance and diagnostic turbulence terms, fully integrated with existing Navier-Stokes modules. A turbulent lid-driven cavity at a Reynolds number of approximately 10,000 is used for verification. MOOSE shows the robust solver convergence and produces the turbulent features. But it underpredicts the velocity profile and turbulent quantities, emphasizing the need to develop improved SA near-wall treatments (e.g., low-Re corrections or wall functions) as a key direction for future work.

11 - NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Production of Fischer-Tropsch Synfuels at Nuclear Plants

A case study analysis was performed to evaluate nuclear-powered synthetic fuel production in the midwestern United States (U.S.). A Fischer-Tropsch (FT) fuel synthesis plant design was used as the basis for the analysis. The FT plant design was configured to produce a product slate consisting of diesel fuel, jet fuel, and motor gasoline blend stocks from carbon dioxide (CO 2 ) and hydrogen (H 2 ) feedstocks. The CO 2 feedstock for the FT plant was assumed to be sourced from biorefineries in the region around a Midwest light water reactor (LWR) nuclear power plant (NPP). The analysis specifies that power from the LWR is used to produce H 2 via high-temperature steam electrolysis and to operate the FT synfuel production plant. Capital costs were estimated for the FT plant while capital costs for the electrolysis plant were based on previous Idaho National Laboratory (INL) studies. In addition to labor and maintenance costs for the FT and electrolysis plants, operating costs also include the costs for CO 2 feedstock transport. An analysis was performed to determine the cost of transporting CO 2 from the distributed biorefinery sources to the centralized fuel synthesis plant as a function of the synfuel plant capacity and corresponding CO 2 demand. The primary revenue streams are associated with sales of the synthetic fuel products. The synthetic fuel products will likely follow the same market trends as the conventional fuel products. The synfuel price data was thus based on projections made by the U.S. Energy Information Administration (EIA) 2021 Annual Energy Outlook (AEO) for conventional fuel products minus federal and state taxes, as well as marketing and distribution costs. The economic analysis also considered cases that included and excluded revenues from the 2022 Inflation Reduction Act (IRA) clean hydrogen production tax credit (PTC) of $\$ $3.00/kg for the first ten years of operation. The economic analysis calculated the net present value (NPV) for cases involving steady-state synfuel production for comparison with the NPV for a business-as-usual case in which NPP continues to sell only electric power to the grid. A synfuel production “Reference Case” was considered in addition to sensitivity cases in which the plant capacity, electricity price, and synthetic fuel product prices were perturbed. The synfuel production Reference Case considered a scenario in which the electrolysis and synfuel plants utilized a combined electrical load of 1000 megawatt electrical (MWe) from the LWR with the balance of the LWR power output being sold to the electric grid. The economic analysis suggests that the synfuel production Reference Case evaluated in this analysis would lead to considerable economic potential for near-term deployment of a nuclear-based synfuel production plant. Specifically, the economic analysis suggests that the deployment of a 1000 megawatt (MW) nuclear-powered synfuel plant could result in a NPV increase of approximately $\$ $1.7 billion for a case with no clean synfuel price premium relative to conventional petroleum fuels when accounting for the additional revenues from the 2022 IRA clean hydrogen PTCs of $\$ $3/kg. Sensitivity analysis was performed to evaluate the effect of perturbation of selected model input parameters on the NPV for the synfuel production Reference Case. The sensitivity analysis indicates that the plant capacity has the largest impact on the differential NPV, with a smaller synfuel production capacity resulting in a decrease in revenue when a larger fraction of the power from the NPP is sold to the grid and a smaller fraction of the power is used to produce synthetic fuel products. The synfuel product pricing has the next largest impact on the differential NPV, with lower synfuel prices resulting in decreased NPV from decreased synfuel sales revenue while higher synfuel prices result in increased NPV from increased synfuel sales revenue. Electricity pricing has a smaller effect on the NPV than the fuel sales price since, in the Reference Case, most of the energy from the NPP is used for synfuel production and a smaller amount of the system revenues are associated with electrical power sales. However, the electricity price sensitivity does indicate that the Synfuel Integrated Energy System (IES) would have a greater NPV than the business-as-usual case (e.g., grid power sales only) when electricity market prices are low, suggesting that synfuel production could provide a strategy for decreasing the economic risks to NPPs posed by a loss of revenues attributed to falling electricity market prices.

10 SYNTHETIC FUELS↗
NASA NTRS1975

Consideration of probability of bacterial growth for Jovian planets and their satellites

Environmental parameters affecting growth of bacteria (e.g., moisture, temperature, pH, and chemical composition) were compared with current atmospheric models for Jupiter and Saturn, and with the available physical data for their satellites. Different zones of relative probability of growth were identified for Jupiter and Saturn, with the highest in pressure regions of 1-10 million N/sq m (10 to 100 atmospheres) and 3-30 million N/sq m (30 to 300 atmospheres), respectively. Of the more than two dozen satellites, only the largest (Io, Europa, Ganymede, Callisto, and Titan) were found to be interesting biologically. Titan's atmosphere may produce a substantial greenhouse effect providing increased surface temperatures. Models predicting a dense atmosphere are compatible with microbial growth for a range of pressures at Titan's surface. For Titan's surface the probability of growth would be enhanced if (1) the surface is entirely or partially liquid (water), (2) volcanism (in an ice-water-steam system) is present, or (3) access to internal heat sources is significant.

Taylor, D. M.↗
NASA NTRS1996

Analytical Investigation of a Reflux Boiler

A thermal model of a single Ultralight Fabric Reflux Tube (UFRT) was constructed and tested against data for an array of such tubes tested in the NASA-JSC facility. Modifications to the single fin model were necessary to accommodate the change in radiation shape factors due to adjacent tubes. There was good agreement between the test data and data generated for the same cases by the thermal model. The thermal model was also used to generate single and linear array data for the lunar environment (the primary difference between the test and lunar data was due to lunar gravity). The model was also used to optimize the linear spacing of the reflux tubes in an array. The optimal spacing of the tubes was recommended to be about 5 tube diameters based on maximizing the heat transfer per unit mass. The model also showed that the thermal conductivity of the Nextel fabric was the major limitation to the heat transfer. This led to a suggestion that the feasibility of jacketing the Nextel fiber bundles with copper strands be investigated. This jacketing arrangement was estimated to be able to double the thermal conductivity of the fabric at a volume concentration of about 12-14%. Doubling the thermal conductivity of the fabric would double the amount of heat transferred at the same steam saturation temperature.

Simon, William E.↗
NASA NTRS1998

Modeling of a Two-Phase Jet Pump with Phase Change, Shocks and Temperature-Dependent Properties

One of the primary motivations behind this work is the attempt to understand the physics of a two-phase jet pump which constitutes part of a flow boiling test facility at NASA-Marshall. The flow boiling apparatus is intended to provide data necessary to design highly efficient two-phase thermal control systems for aerospace applications. The facility will also be capable of testing alternative refrigerants and evaluate their performance using various heat exchangers with enhanced surfaces. The test facility is also intended for use in evaluating single-phase performance of systems currently using CFC refrigerants. Literature dealing with jet pumps is abundant and covers a very wide array of application areas. Example application areas include vacuum pumps which are used in the food industry, power station work, and the chemical industry; ejector systems which have applications in the aircraft industry as cabin ventilators and for purposes of jet thrust augmentation; jet pumps which are used in the oil industry for oil well pumping; and steam-jet ejector refrigeration, to just name a few. Examples of work relevant to this investigation includes those of Fairuzov and Bredikhin (1995). While past researchers have been able to model the two-phase flow jet pump using the one-dimensional assumption with no shock waves and no phase change, there is no research known to the author apart from that of Anand (1992) who was able to account for condensation shocks. Thus, one of the objectives of this work is to model the dynamics of fluid interaction between a two-phase primary fluid and a subcooled liquid secondary fluid which is being injected employing atomizing spray injectors. The model developed accounts for phase transformations due to expansion, compression, and mixing. It also accounts for shock waves developing in the different parts of the jet pump as well as temperature and pressure dependencies of the fluid properties for both the primary two-phase mixture and the secondary subcooled liquid. The research effort on which this document partly reports described a relatively simple model capable of describing the performance of a two-phase flow jet pump. The model is based on the isentropic homogeneous expansion/compression hypothesis and is capable of fully incorporating the effects of shocks in both the mixing chamber and the throat/diffuser parts of the pump. The physical system chosen is identical to that experimentally tested by Fairuzov and Bredikhin (1995) and should therefore be relatively easy to validate.

Sherif, S. A.↗
DOE OSTI2022

Optimizing feed modulation for coupled methane and NO x conversion over Pd-Pt/Mn 0.5 Fe 2.5 O 4 /Al 2 O 3 monolith catalyst

Here the impacts of feed modulation (frequency, amplitude) and catalyst design (composition and architecture) parameters are reported for the conversion of methane and NO x over a dual-layer Pt+Pd/Al 2 O 3 + Mn 0.5 Fe 2.5 O 4 /Al 2 O 3 monolith. CH 4 and NO x conversion data show that the dual-layer catalyst outperforms single-layer samples having the same catalyst loadings, with and without spinel. Close proximity of the PGM and MFO functions in the mixed-layer catalyst lowers the CH 4 conversion at high temperature while separating the PGM and spinel layers with an intermediate Al 2 O 3 layer does not. Methane conversion enhancement is linked to its nonmonotonic dependence on O 2 . The performance gains are tied to a transient activity spike that occurs during the lean-to-rich feed transition when water is present in the feed. The transient spike is attributed to the removal of CO and H 2 products via reactions with stored O 2 in the spinel, eliminating inhibition of methane steam reforming.

03 NATURAL GAS↗
DOE OSTI2025

Counter-Current Flow Limitation Studies in Complex Geometries Utilizing Interface Capturing Simulations Coupled with PID Flow Rate Controller

In nuclear thermal-hydraulic studies, counter-current flow limitation (CCFL) typically refers to steam rising at a fast rate such that it prevents coolant from draining down within a confined channel. CCFL is a crucial issue in nuclear reactor safety analysis. This study investigates CCFL in debris bed channels using high-resolution interface-capturing simulations. A novel proportional-integral-derivative flow rate controller is developed to efficiently achieve the CCFL conditions. Verification studies confirm that CCFL occurs under the same conditions with or without the controller, demonstrating that PID control ensures accurate prediction. Three debris bed channel geometries were examined: a cylindrical channel, a channel with small obstacles, and a channel with large obstacles. Results show that obstacles significantly impact flow behavior, interfacial shear, wall shear, and pressure gradients required for CCFL. Furthermore, the comparison with experimental data confirmed that simulations incorporating geometric complexities align more closely with experimental CCFL conditions. A pressure gradient correlation was also developed for CCFL prediction.

Counter-current flow limitation↗
DOE OSTI2023

Prediction of the Inter-Tube Flow Mode Transitions in the Evaporators of Multi-Effect Thermal Desalination Plants

Water is one of the most stressed resources on the planet. The limited availability of fresh water and the high cost of transportation have led to an increased interest in water desalination technologies. The two main categories of desalination techniques are membrane desalination and thermal desalination. Membrane technologies include pressure driven and electrical driven membranes. On the other hand, thermal desalination includes: multi-effect desalination (MED), multi-stage flash (MSF) desalination, and mechanical vapor compression desalination. Multi-effect desalination plants are usually made of a series of evaporators (also known as effects). In each effect, hot steam flows inside the tubes and evaporates the seawater that falls on the outside of the tubes. The vapor formed at each effect flows to the next effect and acts as the heating medium for the falling seawater. The prevailing flow mode of the falling seawater (i.e. droplet, jet, or sheet) influences heat and mass transfer as well as dry out in the evaporators of Multi-Effect Desalination (MED) plants. The objective of this paper is to predict and discuss the prevailing falling film flow modes in the evaporators of MED plants, under different operating conditions. The paper demonstrates the transitional Reynolds numbers between the main falling film modes for seawater. This closes a gap in the literature where there is a dearth of mode transition data for seawater. The effect of fluid properties and tube geometry on the transitions is discussed in details. As a result, the accuracy of the predicted transitional Reynolds numbers is evaluated via uncertainty quantification techniques.

availability↗
DOE OSTI2020

Optical Transmission Spectroscopy of the Terrestrial Exoplanet LHS 3844b from 13 Ground-based Transit Observations

Atmospheric studies of spectroscopically accessible terrestrial exoplanets lay the groundwork for comparative planetology between these worlds and the solar system terrestrial planets. LHS 3844b is a highly irradiated terrestrial exoplanet (R = 1.303 ± 0.022R {sub ⊕}) orbiting a mid-M dwarf 15 parsecs away. Work based on near-infrared Spitzer phase curves ruled out atmospheres with surface pressures ≥10 bars on this planet. We present 13 transit observations of LHS 3844b taken with the Magellan Clay telescope and the LDSS3C multi-object spectrograph covering 620–1020 nm. We analyze each of the 13 data sets individually using a Gaussian process regression, and present both white and spectroscopic light curves. In the combined white light curve we achieve an rms precision of 65 ppm when binning to 10 minutes. The mean white light-curve value of (R {sub p}/R {sub s}){sup 2} is 0.4170 ± 0.0046%. To construct the transmission spectrum, we split the white light curves into 20 spectrophotometric bands, each spanning 20 nm, and compute the mean values of (R {sub p}/R {sub s}){sup 2} in each band. We compare the transmission spectrum to two sets of atmospheric models. We disfavor a clear, solar composition atmosphere (μ = 2.34) with surface pressures ≥0.1 bar to 5.2σ confidence. We disfavor a clear, H{sub 2}O steam atmosphere (μ = 18) with surface pressures ≥0.1 bar to low confidence (2.9σ). Our observed transmission spectrum favors a flat line. For solar composition atmospheres with surface pressures ≥1 bar we rule out clouds with cloud-top pressures of 0.1 bar (5.3σ), but we cannot address high-altitude clouds at lower pressures. Our results add further evidence that LHS 3844b is devoid of an atmosphere.

79 ASTRONOMY AND ASTROPHYSICS↗
DOE OSTI2018

Solid Oxide Based Electrolysis and Stack Technology with Ultra-High Electrolysis Current Density (>3A/cm 2 ) and Efficiency

Hydrogen, a valuable commodity gas, is increasingly recognized as an important fuel and energy storage pathway of the future. This project aims to develop an innovative solid oxide based electrolysis cell and stack technology with ultra-high steam electrolysis current (>3A/cm 2 ) for potentially ultra-low-cost, highly efficient hydrogen production from diverse renewable sources. In this project, solid oxide based high power density cells (HiPoD cells) were developed. Those cells demonstrated capability of operating at ultra-high electrolysis current density of 6 A/cm 2 at 1.67V. During a long term steady state electrolysis test, a HiPoD cell was operated for more than 1000 hours at 3 A/cm 2 with a low degradation rate of 1.8% per 1000 hours. A 20-cell electrolysis stack was built using HiPoD cells and an ultra-compact, low-cost stack design platform. This stack was used to explore the boundaries of high current density electrolysis operation and achieved an incredible stack current density of 3 A/cm 2 with an average cell voltage of only 1.493 V. The stack was further operated in steady-state electrolysis at 2 A/cm 2 for more than 1000 hours with an overall degradation of 0.57% per 1000 hours. With an improved understanding of electrolysis operation at ultra-high current density, a new compact stack architecture (CSA) design with scalability up to 55 kW (or 38 kg H 2 per day) was tested. A number of 45-cell CSA stack was built and demonstrated 10 kW and 245 g/hr hydrogen production at 1.8 A/cm 2 electrolysis current density. In addition to cell and stack development, a preliminary system design was developed by integrating the inputs from electrochemistry, cell/stack performance data, and system level implications of configuration and operational parameters. A module design was created based on a circular array of six stacks surrounded in a cool pressure vessel. Further architectural and controls strategies such as stack power control and instrumentation were determined through the development of the module. A comprehensive techno-economic study of an ultra-high current density SOEC system integrated with renewable energy sources has been conducted. To determine the estimated cost of hydrogen for the system, the H2A Current Distributed Hydrogen Production Model version 3.101 was applied. Annual system production cases at both commercial and industrial electricity rates as per the H2A model was analyzed. The option of meeting DOE 2020 Advanced Electrolysis Technologies targets were discussed. Feedstock electricity represents the bulk of projected hydrogen cost with either electricity rate. At an annual production volume of 250 units, H2A hydrogen cost of $2.3/kg can be achieved at electricity cost around 3.5¢/kWh.

08 HYDROGEN↗
DOE OSTI2016

Pervaporation-assisted catalytic conversion of xylose to furfural

Furfural produced from the biomass-derived xylose may serve as a platform molecule for sustainable fuel production. The Brønsted acid-catalyzed dehydration of xylose to furfural is plagued by side reactions that form a set of soluble and insoluble degradation products, collectively known as humins, which reduce the yield of furfural. The formation of humins can be minimized by removal of furfural, either by steam stripping or by liquid-liquid extraction (LLE). However, both these techniques are very costly. The goal of this study was to demonstrate the feasibility of using pervaporation, a membrane process, to remove furfural as it is produced. A laboratory-scale reactor/membrane system was designed, built, and tested for this purpose and its performance for furfural production was compared with that achieved by carrying out the reaction with and without furfural extraction by LLE. Furfural production assisted by pervaporation (with a commercially available membrane or a triblock copolymer membrane) or LLE produced comparable amounts of furfural, and more than could be achieved by reaction without extraction. A model of the reaction kinetics and the rate of furfural extraction was fit to the pervaporation- and LLE-assisted furfural production data and was used to predict the performances of these processes at near-complete xylose conversion. Here, pervaporation is shown to have two advantages over LLE: pervaporation extracts a greater fraction of the furfural produced and the furfural concentration in the permeate phase is significantly higher than that present in the extractant phase obtained by LLE. It is noted that further improvement in the separation of furfural from the aqueous phase where it is produced can be achieved by using a more-permeable, thinner pervaporation membrane of larger area, and by operating the membrane at the reaction temperature.

Wang, Alex↗
DOE OSTI2020

FINAL TECHNICAL AND ECONOMIC FEASIBILITY STUDY ON THE APPLICATION OF A HEAT INTEGRATED POST-COMBUSTION CO2 CAPTURE SYSTEM WITH HITACHI ADVANCED SOLVENT INTO EXISTING COAL-FIRED POWER PLANT

This report contains the results of a techno-economic assessment (TEA) conducted of a heat integrated post-combustion CO2 capture process with Hitachi advanced solvent for retrofit into an existing coal-fired power plant (but treated as greenfield plant on cost analysis). The process has been developed by the University of Kentucky Center for Applied Energy (UK CAER). EPRI was chiefly responsible for this analysis, with significant input from WorleyParsons, Hitachi Power Systems America (Hitachi) and UK CAER. The project also involves the design, fabrication, installation, testing, and analyses of a slipstream facility located at L&GE-KU’s E.W. Brown Generating Station to demonstrate the UK CAER carbon capture system that could utilize heat integration with the main power plant. The design, start-up, and baseline of the pilot system was performed with a generic 30 wt% MEA solvent to obtain data for direct comparison with the DOE/NETL Reference Case followed by testing Hitachi’s proprietary solvent H3-1. In this techno-economic analysis, two cases utilizing the UK CAER process are compared, using different approach temperatures and solvent, against the DOE/NETL Reference Case (Case 10). The results are shown comparing the energy demand for post-combustion CO2 capture and the net higher heating value (HHV) efficiency of the power plant integrated with the post-combustion capture (PCC) plant. A levelized cost of electricity (LCOE) assessment was performed showing the costs of the options presented in the study. The key factors contributing to the reduction of LCOE were identified as CO2 partial pressure increase at the flue gas inlet, thermal integration of the process, and performance of the Hitachi H3-1 solvent. Recent UK CAER process pilot-scale testing data and process simualtion data showed that the packing heights of absorber and stripper columns were significantly oversized in the prelimanary TEA (Task 2 of this project) and thus updated in this final TEA for the H3-1 case only. In addition, the solvent make-up cost for H3-1 was updated based on lattest test results. Finally, a heat integration with the main power plant was applied in this final TEA to increase overall energy effciency for both the MEA and H3-1 cases. Additonal reductions in capital and operational costs are expected but not taken into account here. Shorter columns result in reduced pressure drops, smaller blower head and pump hydraulic head requirements. An increase in overall energy efficiency resuls in a decreased size of the power plant, the CCS and a reduced parasitic steam requirement to the CCS. The net efficiency of the UK CAER integrated PC power plant with CO2 capture changes from 26.2% for the Reference Case 10 plant in 2010 revised DOE/NETL baseline report to 27.6% for the MEA options considered, and 29.1% for the options utilizing the Hitachi advanced solvent. The UK CAER Process + Hitachi case also produces an extra 30.9 MW of generation compared to the UK CAER Process + MEA case and total 60.9 MW more than DOE Case 10. LCOE ($/MWh) values are $172.08/MWh for the MEA option and $157.65/MWh for the Hitachi H3-1 solvent cases considered in comparison to $189.59/MWh in January 2012 dollar for the Reference Case 10. The UK CAER CCS process with MEA case lowers energy consumption for CO2 capture to 1340 Btu/lb-CO2 captured as compared to 1540 Btu/lb-CO2 in the Reference Case 10. The UK CAER CCS process with H3-1 case further lowers energy consumption for CO2 capture to 973 Btu/lb-CO2 captured, for an advantage of 36.8% less energy consumption than Case 10. The study also shows 38.1% less heat rejection associated with the carbon capture system from 3398 MBtu/hr (Case 10) to 2104 MBtu/hr for the UK CAER + MEA system. Heat rejection is reduced to 2464 MBtu/hr in the UK CAER + H3-1 case, for a 27.5 % decrease compared to Case 10. Modeling outputs show that in the UK CAER process, the cooling water that is 2-5°C cooler than conventional cooling tower water can be achieved for ambient conditions common to the midwest and other regions. The results from the techno-economic assessment show that the proposed technology can be investigated further as a viable alternative to conventional CO2 capture technology. The evaluation also shows the effect of the critical parameters on the LCOE, with the main variables being the approach temperature and CO2 partial pressure increase at the flue gas inlet. A summary of the key advantages of the UK CAER Process + H3-1 case for LCOE and other economic factors compared to the DOE Case 10 is as follows: • A lower variable operating cost by $1.56/MWh ($1.08MWh less than the UK CAER Process + MEA Case), a 11.7% reduction compared to the DOE Case 10 • A lower COE by $25.32MWh ($13.94/MWh lower than the UK CAER Process + MEA Case), a 16.9% reduction compared to the DOE Case 10 • A lower LCOE by $31.94/MWh ($17.51/MWh lower than the UK CAER Process + MEA Case), a 16.9% reduction compared to the DOE Case 10 • A lower cost of CO2 captured by $18.65/tonne CO2 ($9.44/tonne CO2 lower than the UK CAER Process + MEA Case), a 30.4% reduction compared to the DOE Case 10 • A lower cost of CO2 avoided by $34.95/tonne CO2 ($18.53 tonne CO2 lower than the UK CAER Process + MEA Case), a 38.7% reduction compared to the DOE Case 10

Bhown, Abhoyjit S.↗
DOE OSTI2016

Wabash Valley Integrated Gasification Combined Cycle, Coal to Fischer Tropsch Jet Fuel Conversion Study

This reports examines the feasibility of converting the existing Wabash Integrated Gasification Combined Cycle (IGCC) plant into a liquid fuel facility, with the goal of maximizing jet fuel production. The fuels produced are required to be in compliance with Section 526 of the Energy Independence and Security Act of 2007 (EISA 2007 §526) lifecycle greenhouse gas (GHG) emissions requirements, so lifecycle GHG emissions from the fuel must be equal to or better than conventional fuels. Retrofitting an existing gasification facility reduces the technical risk and capital costs associated with a coal to liquids project, leading to a higher probability of implementation and more competitive liquid fuel prices. The existing combustion turbine will continue to operate on low cost natural gas and low carbon fuel gas from the gasification facility. The gasification technology utilized at Wabash is the E-Gas™ Technology and has been in commercial operation since 1995. In order to minimize capital costs, the study maximizes reuse of existing equipment with minimal modifications. Plant data and process models were used to develop process data for downstream units. Process modeling was utilized for the syngas conditioning, acid gas removal, CO 2 compression and utility units. Syngas conversion to Fischer Tropsch (FT) liquids and upgrading of the liquids was modeled and designed by Johnson Matthey Davy Technologies (JM Davy). In order to maintain the GHG emission profile below that of conventional fuels, the CO 2 from the process must be captured and exported for sequestration or enhanced oil recovery. In addition the power utilized for the plant’s auxiliary loads had to be supplied by a low carbon fuel source. Since the process produces a fuel gas with sufficient energy content to power the plant’s loads, this fuel gas was converted to hydrogen and exported to the existing gas turbine for low carbon power production. Utilizing low carbon fuel gas and process steam in the existing combined cycle power plant provides sufficient power for all plant loads. The lifecycle GHG profile of the produced jet fuel is 95% of conventional jet fuel. Without converting the fuel gas to a low carbon fuel gas, the emissions would be 108% of conventional jet fuel and without any GHG mitigation, the profile would be 206%. Oil prices greater than $120 per barrel are required to reach a targeted internal rate of return on equity (IRROE) of 12%. Although capital expenditure is much less than if a greenfield facility was built, the relatively small size of the plant, assumed coal price, and the CTL risk profile used in the economic assumptions lead to a high cost of production. Assuming more favorable factors, the economic oil price could be reduced to $78 per barrel with GHG mitigation and $55 per barrel with no GHG mitigation.

01 COAL, LIGNITE, AND PEAT↗
DOE OSTI2022

A Process with Decoupled Absorber Kinetics and Solvent Regeneration through Membrane Dewatering and In-Column Heat Transfer (Final Report)

This report summarizes the work conducted on project DE-FE0031604 where University of Kentucky Center for Applied Energy (UK CAER) has validated its intensified CO 2 capture process through substantial enhancements to the kinetics of the absorption process and energy reductions by absorber temperature profile modification, dewatering and heat integration technologies for achieving significant capital and operating cost reductions. To address DOE’s objective of improving post-combustion CO 2 capture technology and reducing associated cost, UK CAER employed an intensified process which combined three key aspects targeted at overcoming inherent limitations or barriers in the conventional CO 2 capture and desorption process. The process designed to be independent of the type of solvent used, included (1) the use of 3-D printed two-channel structured packing material to control the temperature profile and increase the CO 2 absorption rate in the absorber, (2) a zeolite membrane dewatering unit for dewatering of the carbon-rich solvent to decouple solvent concentration needs for CO 2 absorption and desorption, and (3) a rich-split feed with two-phase flow heat transfer prior to the stripper that provided a secondary point of vapor generation to provide energy savings in steam extraction and solvent regeneration. The project was executed over two budget periods. This involved testing of individual process components which included the advanced heat transfer packing and the dewatering membrane on UK CAER’s 30 liter per minute (L/min) CO 2 (3” Column) capture bench unit with simulated flue gas in the first budget period. Subsequent scaled-up testing of these components together with the split-feed configuration were also tested in UK CAER’s 0.1 MWth CO 2 capture unit with coal-derived flue gas in the second-budget period. Long term studies were done during this period to assess process and solvent performance over extended duration. Project partners Lawrence Livermore National Laboratory (LLNL) and Media & Process Technology (MPT) led the development efforts for the advanced packing material and dewatering membrane respectively. Data from the long term testing was used as input for an environmental, health and safety (EH&S) assessment for the process and scaled technology performed by ALL4 LLC. Trimeric Corporation also completed a techno-economic analysis (TEA) for the UK CAER technology which was compared to the DOE reference Case B12B. Tests on the 3” column capture unit showed that the advanced heat transfer packing could be used to lower the bulge temperature in the absorber, and this was also proven in the scaled testing in the 0.1 MWth CO 2 capture unit. The bulge temperature could be lowered by >10 °C, changing the temperature profile in the absorber, and showed potential to enhance absorption with the ability to tailor the profile to provide conditions suitable for a solvent’s properties and kinetics. Conditions for short term evaluation of a 19” zeolite dewatering membrane on the 3” column capture unit yielded desirable fluxes and sustained rejection rates of >80%. However, for the scaled testing of six membrane modules consisting of 21 parts of 31-inch-long membrane tubes in each bundle (surface area 0.3 m 2 ), over a more extended duration, similar rejection rates could not be achieved. With the split-feed of the rich stream to the stripper, improved heat recovery minimized waste heat exiting the top of the stripper. The stripper exhaust temperatures could be reduced by >10 °C; reducing the amount of water vaporization contributed to lowering the regeneration energy by ~ 15%. The energy benefit could be sustained from the long term monitoring of the solvent performance. The solvent properties were not significantly impacted over the long-term operations. The benefits of the UK CAER process demonstrated experimentally were mostly validated from the TEA comparing a commercial scale application of the technology to DOE reference Case B12B. The cost of CO 2 capture for the UK CAER technology was estimated to be ~$34.97/tonne of CO 2 captured; a reduction of 23% compared to Case B12B. The increase in cost of electricity was also shown to be 16% lower than that of Case B12B. The total parasitic demand was also shown to be 11% lower. The key drivers for the benefits are a result of the process intensification approaches employed in the UK CAER technology for enhanced solvent performance, effective heat recovery and improved energy performance. The EH&S assessment did not find any major environmental concerns or barriers to the full scale implementation of the technology.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2023

Grid-Integrated Production of Fischer-Tropsch Synfuels from Nuclear Power

Idaho National Laboratory (INL) investigates the relative economic profitability of an integrated energy system (IES) coupling an NPP with a synfuel production process at selected case study locations across the United States. In the synfuel IES, a high-temperature steam electrolysis (HTSE) plant is thermally and electrically coupled with an NPP to produce zero-carbon hydrogen. The synthetic fuel is produced from this H 2 combined with a CO 2 supply using the reverse water gas shift process followed by the Fischer-Tropsch (FT) reaction. This analysis considers a system in which the CO 2 is sourced from regional CO 2 emitters via the construction and operation of pipeline-based CO 2 supply networks. Locating the FT plant at the same site as the NPP and HTSE plants enables the NPP to provide zero-carbon heat and power to the HTSE plant and zero-carbon power to the FT plant as well as avoid the requirement for long-distance H 2 product transport from the HTSE plant to the FT plant. Hydrogen storage is used to enable the NPP to dispatch power to the electrical grid (instead of the HTSE plant) when grid demand increases, thus enabling the FT plant to continue to operate in a steady-state production mode. The ability to cease hydrogen production for several hours within each day enables the NPP to provide power to the grid to balance the electricity market during peak periods and maximize revenues for the nuclear synfuel IES. The FT process design considered has a 99% carbon conversion efficiency. The use of nuclear energy and nuclear energy-derived hydrogen enables synfuel production to achieve this high level of carbon utilization. Additionally, the life-cycle carbon emissions of the nuclear-based synfuel production process are very low, with WTW emissions of approximately 25 gCO 2 e/MJ, including steam credits (generated from FT process excess heat), and approximately 7 gCO 2 e/MJ, if steam credits are excluded. This compares favorably with the WTW emissions of 90.5 gCO 2 e/MJ for a compression-ignition, direct injection (CIDI) vehicle with a fuel economy of 31.6 miles per gallon gasoline equivalent (MPGGE), using low-sulfur diesel produced using conventional petroleum production and refining processes. Several NPPs in various regions of the U.S. are considered as case study analyses. Supply locations and transportation via pipeline of the CO 2 feedstock to the NPP site are analyzed through the National Energy Technology Laboratory (NETL) CO 2 Transport Cost model. The team finds that the amount of CO 2 generated by different sectors is sufficient for the synfuel production process at all locations considered. The CO 2 transportation costs are functions of the distance of the source to the NPP location, the CO 2 capture cost at the source, and the quantity of CO 2 transported. Historical electricity prices for the NPP case study locations are collected and analyzed. Monthly average prices, price range, and duration of negative-price periods vary among these locations. For each location, an auto-regressive moving average (ARMA) model is trained on historical electricity price data. ARMA validation is done to ensure the synthetic price distributions represent one of historical prices with high fidelity. Synthetic time series from these ARMA models are used in a coupled dispatch and system optimization in the Holistic Energy Resource Optimization Network (HERON) to compute the differential net present value (NPV) of the IES. The team finds that this econometric is positive, ranging from $14M–1.3bn (2020) depending on the location. The optimal synfuel IES configuration to obtain this increase in NPV often maximizes the size of the synfuel production process with regards to the size of the NPP. However, the team shows that the NPP still plays a stabilizing role for the grid: In periods of high prices and high loads, more electricity from the NPP is sent to the grid. A high variability of electricity prices and extreme maximum prices tend to drive up electricity production. While it requires significant investment, the synfuel IES could increase the economic profitability for the existing fleet of LWRs across the country while still maintaining the grid stabilizer role of NPPs. During its lifetime, the main costs for the nuclear synfuel IES are the carbon feedstock transportation costs, followed by the capital expenses (CAPEX) and operation and maintenance (O&M) costs while the revenue comes first from the IRA H 2 production tax credit (PTC) and then from the sales of synfuel products. The profitability of the synfuel IES is most sensitive to the value of the hydrogen PTC and the synfuel products as well as the cost of the carbon feedstock, highlighting the importance of governmental incentives regarding hydrogen, carbon emissions, and synfuel in driving the deployment of future nuclear synfuel IESs.

08 HYDROGEN↗
DOE OSTI2017

Improvement of the RELAP5-3D Model of Condensation in the Presence of Noncondensables

Condensation of steam on the primary side of a steam generator in a pressurized water reactor (PWR) is one means of removing decay heat during some accident scenarios, including small break loss of coolant accident (SBLOCA). However, when noncondensable gasses mix with steam, it impairs condensation. To correctly predict plant behavior, nuclear power plant (NPP) safety analysis codes such as RELAP5-3D must model the effect of condensation in the presence of noncondensables properly. A potential error in the RELAP5-3D code was reported in the condensation model in the presence of noncondensables by the University of Wisconsin (Fu 2015). The report indicated that the calculated condensation heat flux was under-predicted due to the modeling of the mass transfer in the gas mixture. The original documentation describing the implementation of the model was reviewed and compared with alternative formulations. An alternative that uses saturation vapor density at temperature of total pressure instead of the saturation vapor density at vapor partial pressure for calculating vapor mass flux was implemented. Comparison of the alternative method with the original against experimental data for several test cases showed improvement for most test cases.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2015

Update on ORNL TRANSFORM Tool: Simulating Multi-Module Advanced Reactor with End-to-End I&C

The Small Modular Reactor (SMR) Dynamic System Modeling Tool project is in the fourth year of development. The project is designed to support collaborative modeling and study of various advanced SMR (non-light water cooled reactor) concepts, including the use of multiple coupled reactors at a single site. The focus of this report is the development of a steam generator and drum system model that includes the complex dynamics of typical steam drum systems, the development of instrumentation and controls for the steam generator with drum system model, and the development of multi-reactor module models that reflect the full power reactor innovative small module design concept. The objective of the project is to provide a common simulation environment and baseline modeling resources to facilitate rapid development of dynamic advanced reactor models; ensure consistency among research products within the Instrumentation, Controls, and Human-Machine Interface technical area; and leverage cross-cutting capabilities while minimizing duplication of effort. The combined simulation environment and suite of models are identified as the TRANSFORM tool. The critical elements of this effort include (1) defining a standardized, common simulation environment that can be applied throughout the Advanced Reactors Technology program; (2) developing a library of baseline component modules that can be assembled into full plant models using available geometry, design, and thermal-hydraulic data; (3) defining modeling conventions for interconnecting component models; and (4) establishing user interfaces and support tools to facilitate simulation development (i.e., configuration and parameterization), execution, and results display and capture.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2014

Theory and Implementation of Nuclear Safety System Codes - Part II: System Code Closure Relations, Validation, and Limitations

This is Part II of two articles describing the details of thermal-hydraulic sys- tem codes. In this second part of the article series, the system code closure relationships (used to model thermal and mechanical non-equilibrium and the coupling of the phases) for the governing equations are discussed and evaluated. These include several thermal and hydraulic models, such as heat transfer coefficients for various flow regimes, two phase pressure correlations, two phase friction correlations, drag coefficients and interfacial models be- tween the fields. These models are often developed from experimental data. The experiment conditions should be understood to evaluate the efficacy of the closure models. Code verification and validation, including Separate Effects Tests (SETs) and Integral effects tests (IETs) is also assessed. It can be shown from the assessments that the test cases cover a significant section of the system code capabilities, but some of the more advanced reactor designs will push the limits of validation for the codes. Lastly, the limitations of the codes are discussed by considering next generation power plants, such as Small Modular Reactors (SMRs), analyz- ing not only existing nuclear power plants, but also next generation nuclear power plants. The nuclear industry is developing new, innovative reactor designs, such as Small Modular Reactors (SMRs), High-Temperature Gas-cooled Reactors (HTGRs) and others. Sub-types of these reactor designs utilize pebbles, prismatic graphite moderators, helical steam generators, in- novative fuel types, and many other design features that may not be fully analyzed by current system codes. This second part completes the series on the comparison and evaluation of the selected reactor system codes by discussing the closure relations, val- idation and limitations. These two articles indicate areas where the models can be improved to adequately address issues with new reactor design and development.

99 GENERAL AND MISCELLANEOUS↗