Steady-state-coupled fluid flow and heat conduction analysis of a heat-generating solid, as applied to reactor design
Steady-state-coupled fluid flow and heat conduction analysis of heat-generating solid, as applied to reactor design
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Steady-state-coupled fluid flow and heat conduction analysis of heat-generating solid, as applied to reactor design
This report summarizes the results of a collaborative efforts between Oak Ridge National Laboratory (ORNL) and Catalyxx Inc. to investigate scale-up of Catalyxx’s Ethanol upgrading to higher alcohols process. The study was funded by the U.S. Department of Energy (DOE) Bioenergy Technologies Office (BETO) under CRADA (Cooperative Research and Development Agreement) No: NFE-20-08396. The project is part of the Direct Funding Opportunity (DFO) for Computational Science to Enable Bioenergy program which utilized computational toolsets developed by the Consortium for Computational Physics and Chemistry, a multi-laboratory consortium in BETO. The report here summarizes a packed-bed reactor modeling effort spanning the range from lab to industrial scale (from 4 gram to 5-ton catalyst beds), and examining reactor design, process optimization strategies, and suggested design and operating conditions for Catalyxx’s ethanol upgrading plants. The results in this report have been shared in monthly steering meetings and presentations are available in the shared data house owned by Catalyxx. The modeling effort helped to define optimum operation conditions for maximum alcohol selectivity and yield: i.e., temperature control scenarios ranging from adiabatic to isothermal, feed rate, pressure, and inlet H 2 /Ethanol ratio. The modeling results were verified at lab-(4 gram) and pre-pilot (4 kg) scales and has been used to evaluate a 5-ton packed-bed reactor and identify operating conditions to maximize the butanol yield. Special focus was given to understanding mass-transfer effects in the pre-pilot and pilot-scale reactors, over the domain of flow rate, pressure, feed composition, pellet size, shape, porosity, bed voidage, and reactor dimensions (i.e., length/diameter). Modeling was also used to evaluate innovative reactor design concepts such as water removal to improve alcohol selectivity and yield, and a reactor with an additional side inlet to facilitate quenching. These concepts were thoroughly explored, and potential benefits were disclosed. The results in this report are summarized and described qualitatively to protect the IP rights of Catalyxx. The details have been shared with the Catalyxx team in the regular steering meetings. At the end of the project, Catalyxx Inc. announced a successful demonstration of pilot scale operation in Seville, Spain.
In recent years, the alteration of titanium dioxide to become visible-light-responsive (VLR) has been a major focus in the field of photocatalysis. Currently, bare titanium dioxide requires ultraviolet light for activation due to its band gap energy of 3.2 eV. Hg-vapor fluorescent light sources are used in photocatalytic oxidation (PCO) reactors to provide adequate levels of ultraviolet light for catalyst activation; these mercury-containing lamps, however, hinder the use of this PCO technology in a spaceflight environment due to concerns over crew Hg exposure. VLR-TiO2 would allow for use of ambient visible solar radiation or highly efficient visible wavelength LEDs, both of which would make PCO approaches more efficient, flexible, economical, and safe. Over the past three years, Kennedy Space Center has developed a VLR Ag-doped TiO2 catalyst with a band gap of 2.72 eV and promising photocatalytic activity. Catalyst immobilization techniques, including incorporation of the catalyst into a sorbent material, were examined. Extensive modeling of a reactor test bed mimicking air duct work with throughput similar to that seen on the International Space Station was completed to determine optimal reactor design. A bench-scale reactor with the novel catalyst and high-efficiency blue LEDs was challenged with several common volatile organic compounds (VOCs) found in ISS cabin air to evaluate the system's ability to perform high-throughput trace contaminant removal. The ultimate goal for this testing was to determine if the unit would be useful in pre-heat exchanger operations to lessen condensed VOCs in recovered water thus lowering the burden of VOC removal for water purification systems.
Mixed-spectrum reactors (MXR) have been investigated for a wide variety of applications. Typical MXR core designs are based on fast configurations with moderating material inserted within localized regions of the core. Limited analysis has been conducted on assessing important performance and safety aspects. Three main safety-related metrics are devised in this article to validate the feasibility of MXR designs. A long-lived MXR variant was taken as a case study for this analysis. Reactivity feedback mechanisms were evaluated, along with power peaking effects and fast flux damage. Neutron transport simulations found that distortions are manageable in all three areas, with notable improvements in fluence limits and Doppler broadening coefficients. In conclusion, power peaking effects can be significantly dampened by slight addition of gadolinium in the fuel and by carefully selecting the reflector material.
The urgency to deliver fusion power is growing now more than ever, with increasing pressure for both public programs and private companies to meet milestones timelines and overcome significant remaining technical challenges to ensure growth of a nascent fusion industry in time to meet rapidly growing clean energy demands. With incredible advancements in computation and years of investment in fusion model development and validation, integrated modeling is poised to fill a key role in accelerating the timeline to a fusion pilot plant (FPP). Future fusion pilot plants will operate in regimes far beyond current experience, and device design will rely on physics-based prediction and extrapolation. Many concepts will also rely on simulation to assess safety (shielding, tritium management, materials activation and lifetimes), economics and scalability before the decision to build. Importantly, integrated simulation can be used to reveal and solve the complexities of system integration that may otherwise not be apparent in physical components or models developed in isolation. New experimental test facilities that produce relevant conditions to validate and resolve key technical challenges for various subsystems (materials, blankets, fuel cycle, etc.) have been repeatedly called for by the fusion community but are not yet realized. Integrated modeling has an important role in identifying realistic load conditions (thermal, electromagnetic, plasma, neutron and photon loads, etc.) and defining the components and experiments for these test facilities in order to ensure meaningful validation that sufficiently reduces modeling uncertainties and technical risk for the full integrated reactor. The Fusion REactor Design and Assessment (FREDA) SciDAC project is building a component-based integrated modeling framework & data structure to enable self-consistent, multi-fidelity, iterative optimization workflows for the fusion reactor design process. FREDA aims to shorten the time to viable designs by providing a set of flexible workflows to support the various stages of the design process using an integrated model hierarchy, ranging from the simple analytic descriptions to the highest fidelity, theory-based plasma and engineering modeling developed by the fusion and fission communities. These tools are expected to be needed for timely support of FPP design in the milestone program and in the FIRE collaboratives. The plasma simulation backbone of FREDA is IPS-FASTRAN with newly developed coupled Core-Edge Pedestal-SOL (CESOL) workflows, which is being extended to the far-SOL region up to the plasma facing components. FREDA incorporates the FERMI engineering modeling suite and will enable self-consistent evaluation of the thermal shields, limiters, blanket, magnets, and other surrounding structures with predictions of temperatures, erosion, dpa, activation, tritium generation and transport, creep, corrosion, material degradation, etc. Parametric generation of 3D CAD enables rapid iteration of component geometry in response to plasma and loading specifications.
Cell-free systems offer many advantages over traditional biological conversion by eliminating biological growth constraints. It also offers easy manipulation and finetuning of the reaction conditions for each individual enzyme. The conversion of cellulosic glucose to Limonene, a terpene, is a promising pathway for producing fuels and chemicals. Recent advances in developing cell-free systems focuses on bench scale optimization of terpene yield and to demonstrate its feasibility towards commercialization [1,2]. There is significant knowledge gap regarding reaction kinetics of these cell-free systems to further study how it will perform at larger scale. We present here, our studies on reaction kinetics and reactor design implications of cell-free glucose to Limonene conversion to facilitate the further development and commercialization of this process. We developed a novel kinetic model based on the metabolic-network structure of the cell-free system with multi-substrate reversible Michaelis-Menten rate law. To estimate kinetic parameters for this system of rate equations, we employed Bayesian optimization to perform global search with the assistance of gaussian processes to balance exploration and exploitation. The model parameters estimated showed good results compared with experimental data. The estimated parameters were used to perform sensitivity analysis. We found that Hexokinase is one of the most critical enzymes that affect the conversion of the glucose. We also observed that abundance of co-factors is also critical to the conversion of glucose to limonene. We investigated packed bed reactors with enzymes immobilized on the surface of particles to convert glucose stream into Limonene for larger scale production. The reactor design such as particle size, enzyme loading, and flow rate are found to be critical for improving yields. [1] Dudley, Q.M., Nash, C.J. and Jewett, M.C., 2019. Synthetic Biology, 4(1), p.ysz003. [2] Korman, T.P., Opgenorth, P.H. and Bowie, J.U., 2017. Nature communications, 8(1), p.15526.
Neural surrogate models are developed to replace expensive steady-state RANS CFD simulations for valve-controlled pipe flow in nuclear reactor design. Using parametric CFD data generated with MOOSE Pronghorn across a range of valve geometry and flow conditions, three approaches are compared: a POD-based reduced-order model, a structured UNet on a cylindrical grid, and unstructured models (DeepONet and BiStride MeshGraphNet) on nondimensionalized point clouds. POD achieves the highest accuracy (99%) with fast inference but requires storing all solution snapshots, while the DeepONet and BSMS-GNN both achieve ~89% accuracy at sub-second inference, with the BSMS-GNN offering superior geometric generalizability. These surrogates enable rapid ranking of candidate valve designs and can warm-start CFD solvers to accelerate convergence, supporting agentic design iteration on the Prometheus platform.
A six-man, flight prototype carbon dioxide reduction subsystem for the SSP ETC/LSS (Space Station Prototype Environmental/Thermal Control and Life Support System) was developed and fabricated for the NASA-Johnson Space Center between February 1971 and October 1973. Component design verification testing was conducted on the Sabatier reactor covering design and off-design conditions as part of this development program. The reactor was designed to convert a minimum of 98 per cent hydrogen to water and methane for both six-man and two-man reactant flow conditions. Important design features of the reactor and test conditions are described. Reactor test results are presented that show design goals were achieved and off-design performance was stable.
This paper presents a nuclear data uncertainty propagation analysis for two CEA's Sodium-cooled Fast Reactor designs: the SFR V2B and CFV cores. The nuclear data covariance matrices are provided by the DER/SPRC/LEPh's nuclear data team (see companion paper) for several major isotopes. From the current status of this analysis, improvements on certain nuclear data reactions are highlighted as well as the need for new specific integral experiments in order to meet the technological breakthroughs proposed by the CFV core. (authors)
This report presents thermal hydraulics and safety analyses of the 10 MWe Holos-Quad micro-reactor design developed by HolosGen LLC. These analyses were executed under steady-state and station black-out (SBO) transient conditions using the System Analysis Module (SAM), with a focus on ensuring peak fuel temperatures do not exceed the safety thresholds of 1,250°C for steady state normal operating conditions and 1,600°C for transient conditions. For steady-state temperature predictions, a coupled 1D fluid-to-3D solid heat conduction methodology was used. The steady-state simulations included a model of the central core region where power peaking occurs to predict the maximum steady-state fuel temperature, and a coarse-mesh full-core model to provide the initial condition for the consequent transient SBO decay heat removal simulation. The maximum fuel temperature predicted from the central core region simulations under the normal operating condition was 1,222°C, which is below the design limit 1,250°C. To simulate a SBO transient, a full core model was necessary because of the non-axial symmetric core design and heat loss from the outer core structures to the environment. To reduce the required computational costs, a novel scaled subassembly approach was used to model the full core domain. With the full core steady-state temperature distribution provided as the initial condition, the passive decay heat removal of the core was simulated with the scaled subassembly full core model under SBO transient conditions. This analysis showed that the peak fuel temperatures of the Holos-Quad core remained below their steady-state values during the transient, therefore much lower than the safety limit 1,600°C. This is mainly due to the large thermal inertia of the graphite matrix, relatively low power density, and the large surface-to-volume-ratio of the core. The preliminary analyses presented in this report confirm the inherent safety of the Holos-Quad micro-reactor thermal-hydraulics design, as the peak fuel temperatures under both normal and off-normal operational conditions remain within design and safety limits.
In late 2019, INL and ANL agreed to jointly develop the reactor physics code named Griffin based on the integration of the two code suites, MAMMOTH/Rattlesnake (INL) and MC2 - 3/PROTEUS (ANL). Griffin is being developed based on the MOOSE framework and MOOSE quality assurance procedures. This decision was made to be able to allow DOE-NE to efficiently invest funding to this area and to provide effective and timely support for existing and potential users; the latter includes industry and government organizations who are developing various types of advanced reactors in the near and long term. Since MAMMOTH/Rattlesnake has been developed based on the MOOSE framework, the INL/ANL Griffin development team agreed to build Griffin beginning with a merger of MAMMOTH and Rattlesnake into a single code and moving forward by implementing capabilities from the PROTEUS suite into Griffin. Moving forward, both ANL and INL efforts are equally invested in the Griffin project, with management support, to provide an advanced reactor multiphysics tool to assist in reactor design, optimization, and safety analysis. Much work remains in moving Griffin forward to migrate PROTEUS capabilities and to optimize performance to meet user needs. The main objective of this work is to assess the current status of Griffin capabilities in terms of performance and accuracy, to determine priorities for PROTEUS migration, and to identify capabilities and features to improve for supporting the code integration effort. For this assessment, the Empire micro reactor problem that was developed in the ARPA-E MEITNER program was selected as an advance reactor concept of interest to the technical community. The Empire reactor problem was expanded from its original incomplete specification to be a small heat-pipe-cooled micro reactor core with ~113 cm radius and 70 cm in height, composed of 18 fuel assemblies, 12 control drums, and beryllium radial and axial reflectors. In the current model, using 5 cm axial reflectors specified in the original Empire assembly model, more than 10% of neutrons leak axially and through the empty center safety hole, as well as through heat pipe channels in fuel assembly elements that extend through the top reflector region. Several calculation models of the core were defined for systematic assessment, including 2-D and 3-D fuel assemblies and whole cores with cylindrical boundaries. Cross sections were generated using Serpent 2, and meshes were produced using the Argonne mesh tool or the INL neutronics meshing tools combined with CUBIT. Cross sections and meshes were converted to the ISOXML and Exodus formats, respectively, so that Griffin and PROTEUS could use consistent data for solving the reactor problems. With the prepared cross sections and meshes, PROTEUS was run first to ensure that all input data were correctly generated and input options in terms of angle, mesh, and energy group were accurately determined. Comparisons against Serpent 2 solutions were made in terms of eigenvalue and pin power. The same calculations and comparisons were then conducted using Griffin. For the fuel assembly and whole core problems, the PROTEUS eigenvalues agreed well with reference Serpent 2 solutions within 100 and 30 pcm, respectively, and pin power differences relative to Serpent 2 were overall less than 2.2% and RMS 0.8% for the whole core models. This indicated that all input data were properly prepared. Using the same data, Griffin was run selecting the SAAF-CFEM SN solver with Legendre-Gaussian quadrature and NDA and DSA for acceleration. It was found that the SAAF-CFEM solver of Griffin required finer meshes to achieve eigenvalue and pin power solutions in good agreement with Serpent 2, consequently requiring more memory requirement and longer computation time. On the other hand, the SPH-Diffusion 2-D core calculations performed using Griffin were able to recover the exact eigenvalue from the reference Serpent 2 solutions, resulting in a pin-power distribution with an RMS of 0.6% and maximum absolute difference of less than 1.4%. The runtimes for SPH-Diffusion for the 2-D core were less than 3 minutes on 40 cores. During this evolution of this evaluation, many updates were made in Griffin by the Griffin development team of INL (focusing on software updates) and ANL (reviewing and supporting software updates) to complete this assessment. Observations from the code assessment are presented in the conclusion section of this report, followed by a discussion of recommendations for future work.
Risk-informed, performance-based (RIPB) methods have progressed to the point where high-level guidance can be used to augment traditional, deterministic, nuclear safety design practices in areas important to nuclear reactor safety. This paper describes an approach for augmenting the traditional defense-in-depth (DID) qualitative approach with quantitative risk information from a plant-specific probabilistic risk assessment (PRA) in a way that is structured, can be applied on a consistent basis, and allows for clear acceptance criteria. Adding performance-based targets that should be achieved is expected to result in safer and more economical plant designs. Evaluations of DID can be conducted throughout the design process as well as in support of design certification and operating license applications to identify where defense protections could be enhanced or relaxed. Consistent with the United States Nuclear Regulatory Commission's policy statement encouraging greater use of PRA to improve safety decision making and regulatory efficiency, this scenario-based DID method can be used to evaluate changes and overall plant design as part of the normal design control process. Although the RIPB method presented in this paper was developed for application to advanced passive light water reactor designs, the metrics could be tailored to other reactor designs. This risk-informed approach to DID helps to ensure that public and worker risk insights are integrated into the design process holistically.
The current effort is supported by the U.S. Department of Energy (DOE), Advanced Reactor Demonstration Program (ARDP) Regulatory Development, Regulatory Framework Modernization area, which seeks to address potential regulatory challenges for advanced reactor vendors that are currently or will soon be initiating the licensing process. In pursuit of this goal, this effort seeks to aid the advanced reactor industry and regulatory bodies in understanding and addressing the potential occurrence of high-temperature fluid releases in advanced reactor designs as part of licensing and regulatory oversight of operation. Improving the awareness and understanding of the behavior and potential consequences associated with high-temperature fluid release events can ensure that they are appropriately considered and addressed.
Plasma-based water treatment (PWT) is a promising technology that can degrade various emerging contaminants. However, PWT application on an industrially viable scale is hindered by the lack of an efficient reactor design that combines enhanced plasma-liquid contact with high liquid throughput. This work investigates the applicability of a bubble column gas-liquid contactor to PWT. A pulsed plasma bubble column reactor (PBCR) with a concentric rod-cylinder electrode configuration was used to correlate contaminant removal performance with the gas-liquid contact parameters of the bubble column. A surfactant, rhodamine B dye, and a nonsurfactant, caffeine, were used as model contaminants at µM concentration levels. The bubble column characteristics, i.e., gas holdup, bubble size distribution, and gas-liquid area, were measured as a function of superficial gas velocity using image-based methods. Degradation rates of both contaminants increased with gas flowrate. For caffeine, the increase was attributed to intensified bulk liquid mixing, while dye degradation increased due to the increased gas-liquid area. Ultimately, we show that bubble column contactors significantly improve the utilization of plasma-generated reactive species toward contaminant degradation by distributing them over a large contact area. As a result, a better match between the plasma species interfacial flux and the interfacial contaminant concentration leads to improved treatment energy efficiency. Furthermore, typical degradation energy efficiencies were ~10 g/kWh for caffeine and ~60 g/kWh for rhodamine B.
Westinghouse Electric Company is a nuclear reactor vendor headquartered in the U.S. that is developing advanced reactor technology for the U.S. and global markets. Westinghouse has been relying on the neutronics Argonne Reactor Codes (ARC) executed through the NEAMS Workbench and its PyARC module that are developed under the DOE-NE Nuclear Energy Advanced Modeling and Simulation (NEAMS) and Advanced Reactor Technology (ART) – Fast Reactor programs. Through this user experience, Westinghouse identified several enhancements that would benefit the ARC codes’ usability by the US industry and therefore its commercialization potential. The enhancements were proposed to deliver both improvements in workflow and analysis capabilities to better support effective fast reactor core design and analysis to the nuclear industry. The PyARC workflow was extended in this project by integrating non-neutronic ARC codes DASSH and NUBOW-3D. The Ducted Assembly Steady-State Heat equation (DASSH) code is developed at ANL to perform steady-state thermal hydraulic sub-channel analysis in liquid metal fast reactor assemblies to determine optimized coolant flow and temperature distributions, which in this project was updated and validated for lead fast reactor (LFR) applications. The interface between REBUS and NUBOW-3D were improved in this project to assess the impact of the core restraint design and thermal induced expansion effects on the reactivity of the core, and to model the deformations of the fuel assemblies induced by temperature and irradiation. Finally, the ARC models that were extensively verified and validated through various SFR-based modeling benchmarks are extended in this project through code-to-code comparison on relevant LFR-specific neutronics benchmarks against Monte-Carlo neutronic solutions. Overall, this work enables verification of the capability of the ARC codes for a wide range of Generation-IV reactor designs. The outcome of this project is the release of a comprehensive modeling toolkit of validated, robust and efficient codes, as well as their user interface, that enables industry to perform a wide range of fast reactor analyses for design and licensing of their concepts.
Accidents at the Fukushima Dai-ichi reactors as a result of the devastating earthquake and tsunami of March 11, 2011 have not only dampened the nuclear renaissance but have also initiated a re-examination of the design and safety features for the existing and planned nuclear reactors. Even though failures of some of the key site features at Fukushima can be attributed to events that in the past would have been considered as beyond the design basis, the industry as well as the regulatory authorities are analyzing what features, especially passive features, should be designed into the new reactor designs to minimize the potential for catastrophic failures. It is also recognized that since the design of the Fukushima BWR reactors which were commissioned in 1971, many advanced safety features are now a part of the newer reactor designs. As the recovery efforts at the Fukushima site are still underway, decisions with respect to the dismantlement and decommissioning of the damaged reactors and structures have not yet been finalized. As it was with Three Mile Island, it could take several decades for dismantlement, decommissioning and clean up, and the project poses especially tough challenges. Near-term assessments have been issued by several organizations, including the IAEA, the USNRC and others. Results of such investigations will lead to additional improvements in system and site design measures including strengthening of the anti-tsunami defenses, more defense-in-depth features in reactor design, and better response planning and preparation involving reactor sites. The question also arises what would the effect be on the decommissioning scene worldwide, and what would the effect be on the new reactors when they are eventually retired and dismantled. This paper provides an overview of the US and international activities related to recovery and decommissioning including the decommissioning features in the reactor design process and examines these from a new perspective in the post Fukushima -accident era. Accidents at the Fukushima Daiichi reactors in the aftermath of the devastating earthquake and tsunami of March 11, 2011 have slowed down the nuclear renaissance world-wide and may have accelerated decommissioning either because some countries have decided to halt or reduce nuclear, or because the new safety requirements may reduce life-time extensions. Even in countries such as the UK and France that favor nuclear energy production existing nuclear sites are more likely to be chosen as sites for future NPPs. Even as the site recovery efforts continue at Fukushima and any decommissioning decisions are farther into the future, the accidents have focused attention on the reactor designs in general and specifically on the Fukushima type BWRs. The regulatory authorities in many countries have initiated a re-examination of the design of the systems, structures and components and considerations of the capability of the station to cope with beyond-design basis events. Enhancements to SSCs and site features for the existing reactors and the reactors that will be built will also impact the decommissioning phase activities. The newer reactor designs of today not only have enhanced safety features but also take into consideration the features that will facilitate future decommissioning. Lessons learned from past management and operation of reactors as well as the lessons from decommissioning are incorporated into the new designs. However, in the post-Fukushima era, the emphasis on beyond-design-basis capability may lead to significant changes in SSCs, which eventually will also have impact on the decommissioning phase. Additionally, where some countries decide to phase out the nuclear power, many reactors may enter the decommissioning phase in the coming decade. While the formal updating and expanding of existing guidance documents for accident cleanup and decommissioning would benefit by waiting until the Fukushima project has progressed sufficiently for that experience to be reliably interpreted, the development of structured on-line sharing of information and especially the creation of an on-line compendium of methods, tools, and techniques by which damaged fuel and other unique situations have been addressed can be addressed sooner and maintained as new problems and solutions arise and are resolved. The IAEA's new 'WEB 2.0 tool' CONNECT is expected to play a significant role in this and related information-sharing activities. The trend in some countries such as the United States has been to re-license the existing reactors for additional twenty years, beyond the original design life. Given the advances in technology over the past four decades, and considering that the newer designs incorporate significant improvements in safety systems, it may not be economical or technically feasible to retrofit enhancements into some of the older reactors. In such cases, the reactors may be retired from service and decommissioned. Overall, the energy demand in the world continues to rise, with sharp increases in the Asian countries, and nuclear power's role in the world's energy supply is expected to continue. Events at Fukushima have led to a re-examination on many fronts, including reactor design and regulatory requirements. Further changes may occur in these areas in the post-Fukushima era. These changes in turn will also impact the world-wide decommissioning scene and the decommissioning phase of the future reactors. (authors)
Final report for the DOE Fusion Energy Sciences project titled "A Streamlined, Open Source Neutronics Toolkit for Fusion Reactor Design". This project developed unstructured mesh tracking capabilities in OpenMC as well as two shutdown dose rate methodologies, and performed extensive performance improvements and validation of the open source Monte Carlo code, OpenMC.
This report documents the FY25 Theory and Simulation Performance Target (TSPT) of developing an integrated modeling framework for fusion reactor design and assessment (FREDA). Over Q1-Q4, new capabilities were developed across both plasma and engineering domains and demonstrated on an example representation of a Compact Advanced Tokamak with a Dual Cooled Lead Lithium blanket. This represents a first-of-a-kind demonstration of coupled core-to-wall-to-engineering for a reactor. Self-consistent CESOL workflows were applied to provide core, pedestal, and SOL prediction; new modules were developed for energetic particle stability (FAR3D) and transport (TGLF-EP) analysis; and boundary plasma modeling (SOLPS-ITER, BOUT++/Hermes-3) was expanded to evaluate wall and divertor heat fluxes and interface with engineering thermal analysis. A parameterized CAD tool, TRACER, was expanded to generate medium-fidelity divertor, blanket, and coil geometries; OpenFOAM and Diablo workflows were applied for first-wall and divertor thermal analyses with helium cooling; and reduced-order models were created for high-mass-flux divertor cooling. Magnet multiphysics capabilities were verified between Elmer, Diablo, and a new MFEM-based solver, and workflows enable stress, thermal, and neutron-fluence analysis of TF coils with neutronics-driven heating. Nuclear and blanket analysis workflows were demonstrated, including tritium breeding, transport, and CFD-informed thermo-mechanical assessment. Preliminary multi-fidelity uncertainty quantification workflows were applied to boundary modeling codes and shown to achieve variance reductions with fewer high-fidelity boundary simulations. Key findings highlight the challenges of resolving the ITEP gap to find suitable balance between wall and divertor loads, neutron heating, and practical limits of PFC cooling. Next step priorities are to develop automated workflows to check boundary code convergence and detachment, implement tighter physics-engineering CAD provenance tracking, and inclusion of plasma-material interface models for SLAG and tungsten cracking behavior. Collectively, these developments establish sophisticated capabilities for predictive, multi-fidelity, whole-device modeling that integrates plasma physics, materials, magnets, and nuclear engineering to guide pathways to viable Fusion Pilot Plant design points.