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All sourcesNASA NTRSDOE OSTI
DOE OSTI2026

Idaho National Laboratory CY 2025 National Emission Standards for Hazardous Air Pollutants Analysis, Methodology, and Results for Radionuclides

This report details calculations of potential dose—at public receptor locations surrounding the Idaho National Laboratory (INL) Site boundary and INL in-town facilities—from radionuclides reported to be in use and potentially emitted from INL facilities during calendar year (CY) 2025. All calculations were performed in accordance with the requirements of Code of Federal Regulations (CFR), Title 40, “Protection of the Environment,” Part 61, “National Emission Standards for Hazardous Air Pollutants (NESHAPs),” Subpart H, “National Emission Standards for Emissions of Radionuclides Other than Radon from Department of Energy Facilities” (40 CFR 61, Subpart H). Modeling methodology, model-input parameters, and contribution to dose by facility, source, and radionuclide at the maximally exposed individual (MEI) location are also discussed. The information in this report supports the “National Emission Standards for Hazardous Air Pollutants—Calendar Year 2025 INL Report for Radionuclides” (DOE-ID 2026). During CY 2025, the estimated annual potential dose at the INL Site MEI location was 2.45E-02 mrem/yr, up from the previous year, but remaining far less than the regulatory standard of 10 mrem/yr (CFR 40 Part 61, Subpart H). Approximately 92% of the total dose to the INL Site MEI originated from Materials and Fuels Complex sources. Emissions from INL in-town facilities resulted in an estimated annual potential dose of 4.50E-03 mrem/yr to the MEI, down slightly from the CY 2024 estimated dose. Year-to-year variations in estimated annual dose can be attributed to adjustments in laboratory operations, changes to facility infrastructure, and variation in meteorological conditions.

42 - ENGINEERING↗
DOE OSTI2025

ORNL Package Testing Program Overview

When transporting radioactive or hazardous materials, safety and security are top priorities. Packaging and transportation regulations require reliable evidence that containers have passed rigorous performance tests to ensure that the public and the environment are protected from the hazardous nature of the cargo. Because of its long history in energy and security research, Oak Ridge National Laboratory (ORNL) has needed to ship hazardous packages for the past 65 years. Since the 1940s, ORNL has made significant contributions to transportation regulations and has been at the forefront of regulatory testing development. Today, ORNL is a leader in standards development and testing of designs of radioactive material packages. ORNL plays a critical role in ensuring the safe transportation of radioactive materials across the United States by executing rigorous testing campaigns of packages that contain radioactive materials. Early testing activities focused on supporting the development of transportation regulations established by both the International Atomic Energy Agency (IAEA) and the United States. Currently, all package testing activities are performed under the Package Testing Program (PTP) at the Package Evaluation Facility (PEF) located at the National Transportation Research Center (NTRC), which is about 10 miles from the main ORNL campus. The PTP develops and evaluates testing solutions, ensuring that they are safe efficient, and in compliance with regulatory requirements. The vision for the PTP is to be a world-class leader in the evaluation and testing of radioactive and hazardous material packages. The key elements necessary to fulfill this mission are an experienced and professional staff; state-of-the-art facilities, equipment, and instrumentation; and completion of challenging programs and projects important to package transportation. Collaborations with other internal and external organizations play a significant role in building stronger teams and achieving this vision. By adhering to and advancing regulatory standards, ORNL’s PTP supports development of safe and compliant packaging, safeguarding the transportation process from potential risks associated with radioactive material logistics.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2025

Insulation Activation and Contamination in Low-Power Experiments

Among the diverse advanced nuclear reactor concepts being developed are designs that expect to operate at much higher temperatures than conventional light-water reactors, and therefore require alternative materials for components capable of withstanding these extreme temperatures. Insulation is one such component where alternative high-temperature industrial composites are being considered. Low-power experiments can provide an opportunity for advancing our understanding of material behavior under irradiation; however, these experiments are not without occupational hazards. The focus of this paper is the potential for activation of insulating composites when exposed to neutron fluence during reactor experiments, and to discuss the subsequent contamination of the testing area. This paper will also discuss practical measures for preventing the creation and inhalation of activated particulate matter (i.e., dust), such as engineering and administrative controls and personal protective equipment. This paper evaluates the suitability of several insulation materials for use in reactor experiments based on their activation from neutron irradiation. The materials considered are Pyrogel XTE by Aspen Aerogel, Cerablanket and Kaowool by Morgan Advanced Materials, Thermo-12 Gold by Johns Manville, and Maxsil CF6-2000 by McAllister Mills. Although these materials are not yet widely used in the nuclear industry, they are common in other industries due to their thermal insulating properties. These materials produce dust while handling that can pose health and safety hazards, which could be further exacerbated by activation. The analysis presented in this paper utilizes a deterministic method developed to predict the activation source term of the provided insulation materials. The method calculates the atomic density of each element within the composites and simulates their exposure to a specified neutron flux density representative of low power experimental conditions. During the irradiation phase and throughout the extensive cooling period, neutron absorptions and nuclear decays are tracked for relevant isotopes. The residual activity within each composite is then assessed to identify the material with the lowest potential radiological hazard to workers. Dust will be created during installation and removal of insulating materials and may also be generated during the experiment. Contamination of surrounding surfaces due to dispersion is highly likely unless preventative measures are taken. The results of this analysis are used to estimate an internal dose from inhalation of activated dust, which is significantly lower than the allowable whole-body dose. However, the risk of internal exposure may increase if the dust becomes a transport vector for nuclear material. The goals of this paper are to enhance the understanding of the potential activation and contamination hazards from the use of these insulating materials in low-power nuclear experiments and to foster safer work environments through informed decision-making and strategic planning. This work ultimately contributes to a broader understanding of how new non-nuclear materials for advanced reactors impact the radiological safety of co-located workers, helping to ensure the responsible management of radioactive materials during installation and decommissioning activities.

12 - MGMT OF RADIOACTIVE AND NON-RADIOACTIVE WASTE↗
DOE OSTI2026

Relief Zones Enhance the Durability of Ultrathin Membranes in Electrochemical Conversion Devices

Premature failures in electrochemical conversion systems often result when membrane electrode assemblies (MEAs) use ultrathin (≤15 μm-thick) polymer electrolyte membranes, susceptible to mechanical degradation from stress concentrations arising from device-level integration. Herein, relief zones were developed to mitigate mechanical degradation by alleviating excess and nonuniform compression across active areas. Relief zones, created through ablation of carbonaceous diffusion media, enable seamless adaptation across MEA dimensions without need for hardware modifications. Demonstrated using fuel cells as a case study, accelerated stress tests revealed a 6-fold lifetime improvement (∼1500 h) compared to conventional edge-protected MEAs, decoupling device-level engineering effects from material limitations.

accelerated stress test↗
DOE OSTI2024

AOI [1] Advanced Manufacturing of Ceramic Anchors with Embedded Sensors for Process and Health Monitoring of Coal Boilers

Researchers at West Virginia University (WVU) developed methods to fabricate and test ceramic anchors with an embedded sensor technology for monitoring the health and processing conditions within pulverized coal (PC) and fluidized-bed combustion (FBC) boiler systems. The technology included the development of advanced manufacturing processes for 2D/3D printing electroceramic (conductive ceramic) sensor designs within the ceramic anchor microstructure during the manufacturing process. This advanced manufacturing process would allow for the precise control of local microstructure and composition in order to engineer layer-by-layer any protective and electrically active materials within the refractory anchor. This 3D printing technology would permit the rapid and controlled design of the refractory microstructure and embedded sensor design throughout the volume of the ceramic anchor. The work also included a method to interconnect the sensors to boiler shell through the anchor clamp, where the sensor signals will be processed by low-power electronics and transmitted wirelessly to a central processing hub. The end-goal of the program was to produce a ceramic anchor sensor system which would be ready for implementation within a coal boiler, and/or other similar refractory liner systems (such as that in the glass and metal manufacturing areas). The project objectives were to: 1) Define the chemical and microstructural stability, in addition to the electrical properties, of oxide and non-oxide ceramic composites to be embedded within the ceramic anchor compositions that may operate up to 1400ºC; 2) Develop and implement the 2D/3D printing technology to pattern and control the microstructure of the ceramic anchor and embedded sensor circuits; 3) Develop an interconnect technology which will permit easy installation of the ceramic anchors and signal collection at the boiler shell; 4) Develop low power analog electronics and wireless communication hardware to efficiently collect the sensor signal at each processing unit and transmit data to a central hub for data analysis; 5) Demonstrate the smart ceramic anchor system for temperature and liner fracture within a high-temperature processing unit, such as a boiler furnace or glass melting furnace floor/wall liner.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2025

Explicit Dynamic Impact Analysis of the Building 3525 Packages

This report describes the methodology used for the safety basis analysis of the Building (Bldg.) 3525 casks and presents preliminary results for a selected geometry. The specific problem analyzed is a free fall load case onto an unyielding target at various orientations. The various orientations were analyzed to ensure that the packages were subjected to the orientation that causes the most damage. The analysis approach, material modeling, finite element modeling, and results for the selected case are presented, along with a brief discussion of conservatism and uncertainties. The results for the analyzed load cases show that through selected administrative controls, no breach of the container or loss of shielding will occur in the package.

42 ENGINEERING↗
DOE OSTI2025

Total Effective Dose from Radiologic Emissions from INL Facilities for Calculation of Population Dose for the INL 2024 Annual Site Environmental Report

Total effective radiation dose from airborne releases was calculated using air dispersion modeling performed by the National Oceanic and Atmospheric Administration (NOAA) Idaho Falls Office using their HYSPLIT computer model (Stein et al. 2015; Draxler et al. 2013), and the Dose Multi-Media (DOSEMM) dose assessment model (Rood 2019) . The objective of these calculations was to provide a grid of total effective dose across a model domain that encompasses a 50-mile (80-km) radius from any Idaho National Laboratory (INL) Site source. In addition to INL Site sources, releases from the Radiological and Environmental Sciences Laboratory (RESL) (IF-683) and IF-603 located at the INL Research Center (IRC) within the Idaho Falls city limits were also included. Due to tracking limitations, radionuclides released from IF-611 and IF-603 are modeled as released from IF-603. The dose results will be combined with GIS software to compute a total population dose for the calendar year (CY) 2024 and will be reported in the INL Annual Site Environmental Report (ASER). This report does not cover the population dose calculation and only documents generation of the gridded dose file.

42 - ENGINEERING↗
DOE OSTI2026

Redesign of Nuclear Material Storage Container with Additive Manufacturing

The goal of this project is to reduce worker dose and improve criticality safety by improving nuclear material storage containers. The current method of medium to long term (up to 15 years) storage of small amounts of nuclear material is to store it in a stainless-steel flat tube with a copper crush gasket. These containers use 10 bolts to fasten the lid, and the crush gasket must be replaced after every use. Stainless-steel acts as a gamma shield, but there is not any material to account for neutron dose. A redesign of this container should prioritize reducing radiation doses to handlers of the container by reducing the amount of time handlers are exposed to the container and introducing material with effective neutron and gamma shielding mechanics.

42 ENGINEERING↗
DOE OSTI2026

Air attenuation of high power XFEL beams

The Linac Coherent Light Source-II, a high-repetition-rate x-ray free electron laser, produces high average power as well as high peak power. Air is a key radiation safety element, helping to contain the FEL beams from reaching accessible areas. At high average power, air absorption can produce a high temperature and low-density channel along the x-ray beam path. In this case, the x-ray attenuation no longer follows the Beer-Lambert equation, e-μx . Air attenuation measurements were performed with x-rays focused into a gas cell at the LCLS Time-resolved AMO instrument. The air transmission was observed to significantly increase with x-ray power. Simulations were also performed, which include the thermal processes related to the high average power. In comparison to the measurements, the calculated air transmission is higher, confirming that the simulations are conservative and suitable for radiation safety analyses.

42 ENGINEERING↗
DOE OSTI2024

Challenges, Industry Practice, and Research Opportunities for Protection of IBR-Rich Systems

The objective of this technical report is to outline the challenges of protection design for power systems rich in inverter-based resources (IBRs), synthesize current industrial practices, review new approaches from recent literature, and explore future opportunities in protection. IBRs are experiencing widespread adoption across both transmission and distribution systems. When present in significant quantities, IBRs challenge the performance of many traditional protection functions. To address these issues, the industry has developed sophisticated protection schemes that involve advanced relaying techniques in highly engineered pilot projects. However, these schemes are expensive and time-consuming to develop, build, and test. Researchers have proposed a number of new approaches for protection in IBR-rich distribution systems. Despite their potential, these new approaches do not address some major shortcomings of industry approaches stemming from complexity, practical requirements, and reliability.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2025

Sierra Space Technology Collaboration-Advanced Manufacturing of Thermal Protection System Tiles for Space Plane Atmospheric Reentry

Thermal protection systems (TPS) constitute a major material, engineering, and manufacturing challenge for space access. Atmospheric re-entry generates very high heats and requires advanced materials to withstand such conditions. Combining the required materials and integrating them into the vehicle is a major engineering undertaking that often must use creative designs to accommodate the selected materials and systems. Likewise, the manufacture of TPS is costly and challenging; it requires a combination of materials in a range of complex and unique shapes with specialized process conditions. Compounding these challenges, for harsh re-entry profiles or on high heat flux regions of the vehicle, even state of the art TPS is effectively single use and thereby creating a strong economic incentive to improve the TPS materials, integration, and manufacture. This work focuses on the use of ceramic modifications to TPS materials thereby allowing multi flight capability.

99 GENERAL AND MISCELLANEOUS↗
DOE OSTI2026

Leveraging a synthetic biology approach to enhance BCG-mediated expansion of Vγ9Vδ2 T cells

There is an urgent need to develop a more efficacious anti-tuberculosis vaccine as the current live-attenuated vaccine strain BCG fails to prevent pulmonary infection in adults. In this study, we leverage a synthetic biology approach to engineer BCG to produce more (E)-4-hydroxy-3-methyl-but-2-enyl pyrophosphate (HMBPP), an intermediate of bacterial—but not host—isoprenoid biosynthesis via the methylerythritol phosphate (MEP) pathway. HMBPP strongly activates and expands Vγ9Vδ2 T cells, which are unique to higher-order primates and protect against Mycobacterium tuberculosis infection. BCG has been engineered to produce specific ligands and antigens to some success; in contrast, our strategy exploits a self-nonself recognition mechanism in the host via HMBPP sensing, which has not been attempted before. To inform the design of our recombinant strains, we performed synteny analyses of >63 mycobacterial species and found that isoprenoid biosynthetic genes are not operonic across all the 356 surveyed genomes, but some genes are frequently found in pairs. Thus, we generated synthetic loci with the goal of specifically overproducing HMBPP and tested the ability of these engineered strains to induce human Vγ9Vδ2 expansion in an in vitro stimulation assay. We found that BCG expressing a synthetic MEP locus significantly enhanced Vγ9Vδ2 T cell expansion over the wild-type vaccine strain, and overexpression of the HMBPP synthase GcpE alone potently induced Vγ9Vδ2 T cell expansion with no downregulation of other pathway genes. Together these engineered strains present two successful strategies to accumulate HMBPP and overcome feedback inhibition of the MEP pathway.

59 BASIC BIOLOGICAL SCIENCES↗
DOE OSTI2025

Advanced Manufacturing of Thermal Protection System Tiles for Space Plane Atmospheric Reentry

Thermal protection systems (TPS) constitute a major material, engineering, and manufacturing challenge for space access. Atmospheric re-entry generates very high heats and requires advanced materials to withstand such conditions. Combining the required materials and integrating them into the vehicle is a major engineering undertaking that often must use creative designs to accommodate the selected materials and systems. Likewise, the manufacture of TPS is costly and challenging; it requires a combination of materials in a range of complex and unique shapes with specialized process conditions. Compounding these challenges, for harsh re-entry profiles or on high heat flux regions of the vehicle, even state of the art TPS is effectively single use and thereby creating a strong economic incentive to improve the TPS materials, integration, and manufacture. This work focuses on the use of ceramic modifications to TPS materials thereby allowing multi flight capability.

36 MATERIALS SCIENCE↗
DOE OSTI2024

Digital engineering implementation in nuclear demonstration and nonproliferation projects at Idaho National Laboratory

Digital engineering and digital twins are increasingly being used in nuclear energy projects with important impacts. At Idaho National Laboratory, these approaches have been applied in a variety of nuclear energy research, development, and demonstration projects, with key lessons and evolutions occurring for each. In this paper, we describe the use of digital engineering and digital twins in the Versatile Test Reactor design, National Reactor Innovation Center test beds, and nonproliferation analysis of the AGN-201 reactor design. We share key lessons learned for these projects related to tool selection, adoption and training, and working with existing assets versus beginning at the design phase. We also share highlights of future potential uses of digital twins and digital engineering, including using artificial intelligence to perform repetitive design tasks and digital twins to move towards semiautonomous nuclear power plant operations.

98 NUCLEAR DISARMAMENT, SAFEGUARDS, AND PHYSICAL P↗
DOE OSTI2026

Engineering Against Digital Risk in CIP Applications: Cyber-Informed Engineering Use Cases

Cyber-Informed Engineering (CIE) addresses the reality that cyber attacks on engineered systems can have consequences far beyond data loss or disruption of digital networks. When control systems are compromised, safety, reliability, and performance of the physical process itself may be threatened. This presentation discusses engineered controls of 7 categories and the CIE database of controls that provides clear examples and guidance for defining and applying engineered controls in CIE. It explains what engineered controls are, how they differ from information security measures, and how they are integrated into system design.

99 - GENERAL AND MISCELLANEOUS↗
DOE OSTI2024

A Review on Protection Challenges of Transmission Lines Connected to Inverter-Based Resources

Utilities, university researchers, research institutes, and relay manufacturers have performed studies to investigate different aspects of high IBR penetration. Almost all studies support 1) creating international and national standards to regulate the IBRs, 2) revising engineering tools to address shortcomings, and 3) adjusting the protective relay settings to resolve protection problems. This paper summarizes the studies and research conducted in recent years to quantify the impact of IBR penetration on transmission line protection and to identify potential solutions to improve the dependability and reliability of grid protection systems.

14 SOLAR ENERGY↗
DOE OSTI2025

A combined designed CSP and Pfs48/45 infection and transmission blocking vaccine for malaria

Abstract The multiple stages of the malaria parasite life cycle hampers vaccine development. Combining a pre-erythrocytic antigen with a transmission-blocking antigen would target two independent stages of the life cycle for disease control, resulting in a multistage vaccine that can prevent infection and disease transmission simultaneously. Here, we generated a self-assembled ferritin nanoparticle vaccine that simultaneously presents designed immunogens CSPj5c and 17-4 from the infection-blocking circumsporozoite and the transmission-blocking Pfs48/45 antigens. These immunogens were designed, through structure-based approaches, to retain protective epitopes and confer protection upon vaccination. Immunization with CSPj5c-17-4-ferritin nanoparticles conferred protection against challenge with transgenic sporozoites expressingPlasmodium falciparumCSP in mice, and purified IgGs from immunized rabbits elicited potent transmission-reducing activity. Addition of the engineered 17-4 improved the immune responses to CSPj5c and protection from sporozoite challenge. CSPj5c-17-4-ferritin is therefore a promising multistage malaria vaccine with a potential role in malaria control.

Immunology↗