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Emerging Technologies Review: Small Modular Reactors

Project 69643 Task 10 - The Air Force Civil Engineer Center has tasked Pacific Northwest National Laboratory with investigating emerging technologies to inform the Air Force’s understanding of the technology and to guide key considerations for implementing technologies that are resilient and alternative sources to the traditional methods used in the Air Force today. This report provides information about small modular reactor (SMR) technology; the components; and the technological, political, regulatory, economic, environmental, operational, and social considerations using existing, publicly available information from government, international, vendor, and Air Force sources.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Risk Management Overview for Small Business [Slides]

Project Risk Management is a formal process of identifying, analyzing, and responding to negative and positive events that may arise during a project or process lifecycle in order to increase the likelihood that project goals are met on time and on budget.

99 GENERAL AND MISCELLANEOUS↗

Small-Scale Engineered High Flexibility Gasifier

This project advances a small-scale gasification unit as the first step in syngas-based hydrogen, chemicals, and synthetic fuels production. This unit is associated with an enhanced flexibility to different carbonaceous feedstocks including different types of coals, biomass, and plastics. The purpose of the project was to demonstrate feasibility and efficiency of coal pyrolysis in an auger reactor (pyrolyzer); supplemental methane and pyrolysis gas conversion into syngas in a proprietary non-catalytic converter; combined performance of pyrolyzer and non-catalytic converter to convert coal into syngas The proposed technology is based on an application of an intermediate speed pyrolysis at the temperature range 400-600°C as the first stage of biomass processing. At an industrial scale, an incorporation of coal pyrolysis into a feeding machine – auger-reactor allows to decrease its capital cost. At a pilot scale, it permits to employ electricity to build a compact device for testing of downstream equipment. The auger-reactor (pyrolyzer) generates pyrolysis gas and char practically from any carbonaceous feedstocks but their compositions and quantities are determined by their types. Pyrolysis gas is converted into syngas (mix of H 2 and CO) in a novel, proprietary hydrogen flame assisted non-catalytic converter which employs O 2 instead of air as an oxidizer. This reactor (converter) allows an easy adjustment to different pyrolysis gas compositions and tolerates a presence of sulfur and nitrogen contaminants. Our technology assumes carbonaceous feedstocks gasification with oxygen to allow the products H 2 , CO or CO 2 to be not diluted in N 2 and ready for the following synthesis of chemicals and fuels. Due to the same reason, it permits a more efficient CO 2 capture for its transport and storage. An implementation of our small-scale gasification process may overcome economic constrains by a flexible acceptance of coal, biomass, and plastics as well as their unsorted mixtures to make syngas for the following production of pure hydrogen, chemical and/or synthetic fuels.

42 ENGINEERING↗

The Aemulus Project. V. Cosmological Constraint from Small-scale Clustering of BOSS Galaxies

We analyze clustering measurements of BOSS galaxies using a simulation-based emulator of two-point statistics. We focus on the monopole and quadrupole of the redshift-space correlation function, and the projected correlation function, at scales of 0.1 ~ 60 h -1 Mpc. Although our simulations are based on wCDM with general relativity (GR), we include a scaling parameter of the halo velocity field, γ f , defined as the amplitude of the halo velocity field relative to the GR prediction. We divide the BOSS data into three redshift bins. After marginalizing over other cosmological parameters, galaxy bias parameters, and the velocity scaling parameter, we find fσ 8 (z = 0.25) = 0.413 ± 0.031, fσ 8 (z = 0.4) = 0.470 ± 0.026, and fσ 8 (z = 0.55) = 0.396 ± 0.022. Compared with Planck observations using a flat Lambda cold dark matter model, our results are lower by 1.9σ, 0.3σ, and 3.4σ, respectively. These results are consistent with other recent simulation-based results at nonlinear scales, including weak lensing measurements of BOSS LOWZ galaxies, two-point clustering of eBOSS LRGs, and an independent clustering analysis of BOSS LOWZ. All these results are generally consistent with a combination of ${\gamma }_{f}^{1/2}{\sigma }_{8}\approx 0.75$. We note, however, that the BOSS data is well fit assuming GR, i.e., γf = 1. We cannot rule out an unknown systematic error in the galaxy bias model at nonlinear scales, but near-future data and modeling will enhance our understanding of the galaxy–halo connection, and provide a strong test of new physics beyond the standard model.

79 ASTRONOMY AND ASTROPHYSICS↗

Orbital Debris IC Report

We started a simulation campaign in support of our ongoing plasma signatures of small orbital debris project SINTRA program funded by IARPA. This project aims to identify plasma signatures generated by the interaction of small orbital debris (>10cm) with space plasma that can be used for detection, tracking and eventually, develop technologies to remove these small but lethal objects. The small orbital debris problem is increasing exponentially threaten the current and future use of space.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Large Program Design [Slides]

A slideshow presentation describing how different writing small software coding projects is from writing large software coding projects. It can be OK to just throw together code that is small, single-purpose, and short-lived, but there's more need for good design if the code has to live longer, give highly reliable results, be easy to use, get bigger/cover more physics, cover more application domains. Larger projects also need good code if they are to have more widely-distributed users, have more developers work on it, run larger problems, or run on new architectures.

97 MATHEMATICS AND COMPUTING↗

2021 Small Turbine Certification Awardee: Intergrid LLC

Currently, there are no U.S., fully certified inverters for wind turbines in the 10-15-kilowatt (kW) range. The federal government's Competitiveness Improvement Project (CIP) and Small Business Innovation Research programs present the most viable paths for manufacturers in the distributed wind energy industry to conduct research, develop their products, and, ultimately, commercialize them. Through CIP, Intergrid LLC is reducing the cost, size, and weight of its legacy inverter for distributed wind turbines while increasing efficiency, reliability, and serviceability. To accomplish this, Intergrid will address three areas related to power electronics for distributed wind turbines: (1) Software verification and functional safety certification; (2) Simulation for grid-interconnecting testing; (3) Component alternatives that reduce cost and improve reliability and serviceability. The first two areas relate to long-term management of inverter software, which, for grid-connected inverters, must comply with three standards - one issued by Underwriters Laboratories (UL) and two issued by the Institute of Electrical and Electronics Engineers.

CIP↗

Determining the Effects of Neutron Irradiation on the Structural Integrity of Additively Manufactured Heat Exchangers for Very Small Modular Reactor Applications, DOE Final Report (Project # 19-16980)

Auburn University (AU) teamed with the University of Missouri Research Reactor (MURR) and Kansas State University (KSU) to determine how to best use laser-powder bed fusion (L-PBF) additive manufacturing (AM) methods for generating radiation resistant nickel-based superalloys, Inconel alloy 625 and 718, for special purpose reactor (SPR) or very small modular reactor (vSMR) heat-exchangers (HeXs). Compact, conformal, and durable HeXs that are tolerant of extreme environments are needed for supporting the technical maturity of next-generation, portable compact reactors. AM is an enabler for realizing this new wave of HeXs – providing a means to make customizable hot and cold stream architectures with novel flow path geometries (e.g., tortuous channels with non-uniform, asymmetric cross-sections) and reduced layer-to-layer contact resistance (i.e., no separate bonding procedure required). AM further enables a more time/cost efficient means for fabricating SPRs by reducing the number of suppliers required for HeX assembly and allowing for on-site HeX fabrication. The project aim has been to better understand how neutron irradiation affects the microstructure and properties of additively manufactured nickel-based superalloys, to accelerate their safe, reliable use in the modular reactor industry. The major objective was to qualify/quantify the microstructure and microhardness of nickel-based superalloys (including Inconel 718 and 625) additively manufactured via the L-PBF process in the neutron-dosed (irradiated) and non-irradiated states over a course of 3 years. Effects of build orientation during L-PBF and post-AM heat treatments on neutron resistance, microstructure and mechanical properties were also investigated. Neutron damage mechanisms via hardening were characterized. This project combined subject-matter experts in AM, mechanical/microstructure metallic part characterization, and neutron irradiation, as well as unique assets and capabilities at AU and MURR at MU, to ensure project results translated to effectively addressing known gaps in nuclear science and engineering. Parts were fabricated using L-PBF systems readily available at AU. Specimens were then irradiated using MURR facilities; a manipulator equipped hot cell was also used to measure material hardness after dosing. MURR, a 10 MW, light-water nuclear reactor, is the largest, highest powered, highest-flux university owned research reactor in the U.S. The major findings in this project provide evidence that AM can serve as an alternative way to build structural components for future advanced small modular reactors using advanced materials like Inconel 625 (IN625) or Inconel 718 (IN718). After full spectrum neutron irradiation, vertically as-built AM IN625 samples were observed to display better resistance towards radiation-induced-hardening defects relative to traditionally machined metals. A Vickers microhardness tester, using settings of 1 kgf and dwell time of 15 seconds per indentation, was used to measure hardness in this study. The as-built, vertically printed samples experienced 1.2% of radiation hardening vs. 5.25% radiation hardening observed in wrought IN625. Another set of IN625 and IN718 samples were exposed to fast neutron irradiation. It was observed that IN718 showed more resistance towards radiation hardening compared to IN625 samples indicating IN718 had a better performance. Results showed that the IN718 samples experienced less change (-2.5 to 3.24 %) in microhardness. On the other hand, IN625 samples underwent more (0.9 to 7.21%) change in microhardness after fast neutron irradiation. AM IN625 samples were irradiated using an ion (proton) beam in cyclotron. The mechanical properties of AM samples post irradiation were compared with wrought samples. The irradiated region on the samples were tested using nano-hardness indention. It was observed that the beam current and time used in this study generated an annealing effect and thus reduced the hardness of the samples. The sum of the project results provide precious insight into how one may minimize radiation hardening in AM materials while maintaining material property constraints. Results should assist engineers in selecting an appropriate heat treatment for AM nickel-based superalloys for increased radiation resistance. Results should increase confidence levels for adopting AM for building nuclear reactor components which perform the same or better than conventionally manufactured components. Fast neutron irradiation testing provided an accelerated means of obtaining radiation effects without making materials radioactive and difficult to handle.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗

Projections of wildfire risk and activities under 1.5 °C and 2.0 °C global warming scenarios

Wildfires are important ecosystem processes that have a significant impact on terrestrial vegetation, environment, and climate. This study investigates how future wildfire risk and activities could change under 1.5 °C and 2.0 °C warming scenarios relative to pre-industrial levels using a modified McArthur Forest Fire Danger Index (FFDIn) and the CLM4.5-BGC land surface model. Sixteen Earth System Models (ESMs) from CMIP5 and CMIP6 were employed to supply the variables of climate change under low, middle, and high greenhouse emission scenarios in the 1.5 °C and 2.0 °C scenarios. The ensemble means from the FFDIn and results from the CLM4.5-BGC with multiple forcings show that the dry areas in the southwestern US, Brazilian Highlands, and Arabian islands are projected to face higher wildfire risk with larger burned areas and more carbon emissions under a warmer climate. The Congo Basin and part of the Amazon could have a lower wildfire risk with smaller burned areas and less carbon emissions. The absolute changes in the projected FFDIn are small, although large increases are observed in boreal areas, particularly in the winter and spring. Burned area and carbon emissions are projected to increase in general in the boreal area but decrease in northeastern Asia. Compared to the 1.5 °C scenario, the wildfire risk and burned area levels are projected to increase under the 2.0 °C scenario except in the western Amazon. However, fire carbon emissions are projected to decrease more in tropical areas under the 2.0 °C scenario. The different change directions in eastern North America and eastern China produced by the FFDIn and CLM4.5-BGC suggest the potential effect of non-meteorological elements on fire activities.

1.5 °C and 2.0 °C warming↗

Catalyst design for small molecule activation of energy consequence

This project targets the conversion of ubiquitous small molecules (e.g. NO, CO, H 2 O) into viable precursors to synthetic fuels. Current state of the art catalyst design has not directly targeted transition metal complexes capable of mediating the multi-electron redox processes necessary to reduce the overpotential (energy loss) required achieve efficient activation of small molecule substrates. In this vein, a new strategy has been developed for the assembly of polynuclear architectures; allowing for the construction of tunable polymetallic centers that assemble easily within a pre-organized template (conferring stability, selectivity and tunability) that can effect multi-electron redox processes for reactions. Catalyst development has commenced with the following target design elements: (1) catalysts featuring multiple transition metal ions in the same reaction space to greatly expand accessible molecular redox capabilities; (2) catalysts are assembled in a polynucleating ligand framework that permits control over the cluster morphology as well as the local steric and electronic environment of the transition metal ions within the cluster. The high-tunability of the catalyst composition (metal content) and geometric flexibility has permitted a rigorous assessment of electronic-structure-to-function relationship to be developed, further guiding synthetic efforts to realize more potent catalysts. The numerous permutations possible showcase the high degree of generality to this approach with many synthetic handles to tune redox and reaction chemistry. Trinuclear complexes have been synthesized featuring homo- and hetero-trinuclear cores featuring a variety of first row transition metal ions (Cr→Ni). The molecular clusters have been shown to successfully mediate multi-electron redox processes in a cooperative fashion without requiring strong chemical reductants or oxidants. The reactive molecular complexes are being utilized to activate and breakdown the robust bonds within typical waste stream small molecules (e.g., greenhouse gases) and convert them into value-added commodity chemicals. Ultimately, the catalysts developed by this approach will be required to convert energy acquired via renewable resources (e.g., solar or wind) into synthetic fuels as an energy storage mechanism.

10 SYNTHETIC FUELS↗

2021 Prototype Manufacture and Installation Awardee: Pecos Wind Power, Inc.

Through the 2021 Competitiveness Improvement Project (CIP), Pecos Wind Power will manufacture a prototype of its 85-kilowatt (kW) horizontal-axis distributed wind turbine, the PW85, a new wind turbine that began development in 2017 when the company was founded. The PW85 wind turbine includes an industry-leading rotor diameter (30 meters) and full-span variable pitch blades to target a levelized cost of energy (LCOE) of $0.103/kilowatt-hour in low annual wind speeds (6 meters per second). This is 55% lower than the average small wind turbine project installed in 2018. The goal of this project is to spur the development of increasingly lower-cost, high-capacity-factor distributed wind turbines. As a result, Pecos Wind Power will manufacture and install wind turbines that increase the geographic area in which distributed wind power is cost competitive with retail-priced electricity and other distributed energy resources - primarily solar energy.

CIP↗

blastforge

BlastForge is a python module meant to aid reinforcement learning research for geometry optimization research projects. The code is built to use PyTorch as a backend and will contain several model architectures and reinforcement learning training loops as well as helper python functions to evaluate a model’s performance during and after training. BlastForge is meant to be a small, focused python project to study moderate-complexity geometry optimization problems

Hickmann, Kyle [Los Alamos National Laboratory]↗

Implementation of an Experimental Setup Based on the Three-Omega Method for Thermal Conductivity Measurements of Molten Salts

Molten salt reactors (MSRs) are one of the most promising next-generation nuclear reactor designs which use molten salts as the fuel and coolant. To design, model, predict, license, and operate MSRs, the behavior of the fuel and coolant must be understood as a function of temperature and irradiation, i.e., burnup. Of particular importance and complexity is the reliable and reproducible measurement of thermal conductivity of molten salts at high temperatures (> 500 °C). Thermal conductivity provides information on the rate at which heat passes through a specified material and is dependent on chemical composition. Currently, in the national laboratory complex, several methods for measuring thermal conductivity on molten salt systems are under development, however, to date, consistent data have not been produced. Typically, thermal conductivity measurements of high-temperature melts have been conducted by using the Transient Hot Wire (THW) method where thermal conductivity is determined by the change in temperature over time at a certain distance from a heating wire. Another time-dependent technique is the laser flash method, commonly used for solid samples. Laser flash requires prior measurements of density and heat capacity to calculate the thermal conductivity of the sample, introducing additional measurement errors. Steady state and time-dependent measurements such as THW and laser flash have errors from convection and ambient temperature fluctuations (heat radiation). In order to produce high fidelity thermal conductivity data, a measurement technique needs to be developed that will reduce the effect of convection at high temperatures by measuring in a very fast time window. In addition, to measure on actinide and irradiated salts the sample size should be small. Therefore, this project aims to develop a frequency-domain technique based on the three-omega (3?) method, previously proven to work on solids, nanofluids and low temperature solar salts (25 to 250 °C). If the 3?-device can be designed with materials that can withstand high temperatures (>500 °C) and can be configured to reduce errors due to convection, then it would prove to be a valuable technique for ensuring thermal conductivity on molten salt systems needed for MSR development. For this proposal, the 3? instrument will be designed, assembled, and tested on non-radioactive salts before being used on actinide bearing salts. In addition, a thermal model will be developed to determine the thermal conductivity of the sample from the measured thermal oscillation of the sensor. Because 3? is a direct method that requires a small volume of sample and works in a very fast time window, it will aid in suppressing the interference due to convection which is ideal when working with high temperature liquid samples.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

A Synoptic System for Capturing Ecosystem Control Points Across Terrestrial‐Aquatic Interfaces

Interconnected landscape features such as terrestrial‐aquatic interfaces play an outsized role in biogeochemical cycles as ecosystem control points, but it is notoriously challenging to characterize these. Here, we document a synoptic sensor network design that is (a) flexible to accommodate diverse ecosystem interfaces and gradients, (b) adaptable to monitoring and modeling needs of small and large projects alike, (c) standardized for intercomparability across sites and field experiments, and (d) adequately replicated to capture heterogeneity of each parameter monitored. This real‐time monitoring of surface water, groundwater, soil, and vegetation supports configuration and evaluation of models that span upland, wetland, open water strata, and transitions between them. We established the network at seven sites along the Chesapeake Bay and Lake Erie coastlines, including large‐scale flood manipulation experiments in both regions. A central design element is “one data logger program to rule them all”—a collection of sensor‐specific modules deployed on 40 loggers controlling ∼2,000 sensors, with the goal of streamlining maintenance, debugging, and reproducible data processing. The network generates ∼6 M observations per month, capturing system dynamics at the broad spatial and fine temporal scales needed to initialize and benchmark models; measurement frequency can be modified remotely to capture events. This network design has also revealed behaviors not represented in Earth system models, such as transient groundwater oxygen pulses. Completely documented and open source, this standardized, flexible, and efficient sensor network design can reduce barriers to understanding environmental changes and ecosystem responses across systems and scales.

Ward, Nicholas D. [Pacific Northwest National Labo↗

The VMM3a ASIC

The VMM3a is a custom low-noise Application Specific Integrated Circuit. It is intended to be used in the front end readout electronics of both the Micromegas and sTGC detectors of the ATLAS New Small Wheels upgrade project at CERN. It is fabricated in the 130 nm GlobalFoundries 8RF-DM process. Here, the 64 channels with highly configurable parameters, although designed for a specific project, can meet the processing needs of signals from various detector types in several other applications. In this note, the VMM3a, which is the production version of the VMM family, will be presented along with the features incorporated and its performance.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗

2020 State of the Science Report, Chapter 14: Summary and Path Forward

The 2020 State of the Science report collates and presents the current understanding of interactions between marine renewable energy (MRE) systems and the marine environment, with an emphasis on their effects on marine animals, habitats, and oceanographic systems, using publicly available information. The report places this information in context through lessons learned from research studies in the laboratory and in the field, modeling simulations, and deployments; monitoring around demonstration, pilot, and small commercial MRE projects; and identifies gaps in knowledge and makes recommendations for filling those gaps. In addition, strategies for moving toward a consistent and effective consenting or permitting (hereafter consenting) process and management of the potential effects of MRE development are highlighted. The status and recommendations from each of the priority interactions between MRE devices and the environment are summarized here, and the management strategies for facilitating development are discussed. Finally, a path forward toward commercial MRE development is explored. https://tethys.pnnl.gov/publications/state-of-the-science-2020-chapter-14-summary-path-forward

16 TIDAL AND WAVE POWER↗

Predictive Models for Ceramic Additive Manufacturing

This was a collaborative effort between LLNS, as manager and operator of Lawrence Livermore National Laboratory (LLNL) and RSI, to develop predictive criteria for evaluating the structural integrity of new part designs during the thermal process. The DOE Small Business Voucher project was originally designated as a 12-month project and consisted of four (4) major tasks.

25 ENERGY STORAGE↗

Improving the Economic Viability of Biological Utilization of Coal Power Plant CO 2 by Improved Algae Productivity and Integration with Wastewater Treatment

The overall goal of this project was to improve the cost-effectiveness of systems using algae to capture and beneficially utilize CO 2 from the flue gas of coal-fired power plants. Algal biomass cultivation is an attractive alternative for carbon capture and utilization because it can uptake more CO 2 per land area than any other photosynthetic crop. Also, the resulting biomass can be used to make valuable large-market commodity products, such as biofuels and animal feed. However, the use of algal carbon capture has been limited by several factors including: (1) high costs for growing algae (>$\$1,300$/ton), (2) large land requirements for algae cultivation, and (3) environmental concerns about the large amount of water and nutrient inputs needed for growing algae. This project has taken direct aim at resolving these key limitations and demonstrated several viable approaches to improve the economic and environmental feasibility of algal carbon capture. In particular, this project demonstrated a significant increase in average annual algal productivity from baseline values of 8 g/m 2 -day to above 20 g/m 2 -day. This supports a much lower projected cost of algae production (<$\$500$/ton) and reduces land requirements by more than 50%. Additionally, this project confirmed the ability to grow multiple algae species with wastewater nutrients, which facilitates the potential for substantial new revenue streams for algae cultivation based on tipping fees for nutrient laden wastewater. This study highlighted that there is more potential value in wastewater nutrient treatment credits than in the primary commodity products made from algae. The use of wastewater inputs also mitigates the concerns associated with the large amount of water needed for growing algae. The algal biomass grown for this project using wastewater and simulated flue gas inputs were characterized for potential use as an animal feed ingredient. The algae had a protein content in the range of 35-40%, which is between some common commodity animal feed products— distiller’s grains (~25-30% protein) and soybean meal (45-50% protein). In-vitro digestion tests using cattle rumen fluids, showed that this algae biomass was best suited for use as “bypass protein”, which is digested in the animal intestine. Based on the protein content and amino acid profile of the algae grown in this study, it was estimated to have market value in the range of $\$190$-$\$280$/ton. There is potential for higher value feed products if the algae content of omega-3 fatty acids or antioxidants is accounted for. This project also did small scale demonstration of forward osmosis algae dewatering and nanofiltration of hydrothermal liquefaction aqueous products, which were shown to improve the cost and energy balance for producing algal products. When all the improvements demonstrated in this study were included in techno-economic analysis, it showed there was a viable pathway to profitable algal CO 2 utilization with a payback period in the range of six to ten years.

01 COAL, LIGNITE, AND PEAT↗